Continuous counter-current reactor

Abstract

The present patent disclosure relates to a method and a counterflow reactor system for allowing an abrasive slurry to react with a fluid. The counterflow reactor system comprises a counterflow reactor comprising a slurry inlet at a first side of the counterflow reactor, a slurry outlet at a second side of the counterflow reactor opposite the first side, and a fluid inlet configured to introduce the fluid into the counterflow reactor and such that, in use, at least a portion of the introduced fluid flows in a direction opposite to the flow of the abrasive slurry. The method comprises the steps of introducing an abrasive slurry through the slurry inlet, introducing a fluid through the fluid inlet, allowing the abrasive slurry to flow through the counterflow reactor from the slurry inlet towards the slurry outlet, and allowing at least a portion of the introduced fluid to flow counter-currently to the flow of the abrasive slurry and to react with the abrasive slurry.

Description

Technical Field

[0001] This patent disclosure relates to a method and countercurrent reactor system for allowing abrasive slurries to react with fluids. Background Technology

[0002] The reaction between abrasive slurries and fluids typically requires mixing to be efficient. Therefore, the reactor system, reactor, and internal components used in the process are exposed to the moving abrasive slurry, resulting in continuous wear and requiring maintenance and / or replacement.

[0003] Furthermore, the reaction efficiency between abrasive slurries and fluids typically increases with the mixing rate, thus leading to higher equipment maintenance requirements.

[0004] The reaction between abrasive slurries and fluids has recently attracted increasing attention, for example, due to the potential to reduce atmospheric carbon dioxide concentrations through reactions with minerals, a process known as mineral carbonation. Some of the minerals associated with mineral carbonation are silicates and / or carbonates, such as olivine, wollastonite, serpentine, or steel slag, which can react with carbon dioxide to form carbonate materials. However, the reaction rate between these minerals and carbon dioxide is low under environmental conditions, and this rate is affected by temperature, pressure, and pH.

[0005] One way to accelerate the reaction rate is to allow a mineral-containing slurry to react with a fluid containing carbon dioxide. These slurries facilitate the mixing and processing of carbon dioxide and minerals and allow for controlled reaction under specific conditions. The reaction rate can be further increased by altering the reaction conditions, such as temperature and pressure.

[0006] Furthermore, mineral carbonization reactions can be exothermic or endothermic, and it may be necessary to balance the temperature in the reactor during processing.

[0007] Reactors typically used for mineral carbonization include moving parts for mixing abrasive slurries and piping for controlling reactor temperature.

[0008] Therefore, there are disadvantages associated with reactor systems traditionally used for reactions between abrasive slurries and fluids. Summary of the Invention

[0009] One of the purposes of this patent disclosure is to overcome the shortcomings of the prior art and improve reactor systems and methods for allowing abrasive slurries to react with fluids.

[0010] According to a first aspect, a method is provided in a countercurrent reactor system for allowing an abrasive slurry to react with a fluid, the countercurrent reactor system comprising a countercurrent reactor including a slurry inlet located on a first side of the countercurrent reactor, a slurry outlet located on a second side of the countercurrent reactor opposite to the first side, and a fluid inlet. The method includes the steps of: introducing an abrasive slurry into the countercurrent reactor through the slurry inlet; introducing a fluid into the countercurrent reactor through the fluid inlet; allowing the abrasive slurry to flow from the slurry inlet toward the slurry outlet through the countercurrent reactor; and allowing at least a portion of the introduced fluid to flow countercurrently to the flow of the abrasive slurry and react with the abrasive slurry.

[0011] By allowing the fluid to flow counter-currently relative to the abrasive slurry, the particles of the abrasive slurry are exposed to the fluid, and the fluid can dissolve in the abrasive slurry, which increases the reaction rate. The method also keeps solids suspended and reduces settling within the countercurrent reactor. Furthermore, the counter-current flow of the fluid relative to the abrasive slurry confines the volume containing the fluid. By confining the volume containing the fluid, wear on components such as pumps is reduced.

[0012] In some embodiments of this disclosure, the fluid inlet is located on the second side of the countercurrent reactor.

[0013] In some embodiments, the fluid is a gas or a supercritical fluid. In some embodiments, the gas or supercritical fluid is carbon dioxide. In some embodiments, the abrasive slurry comprises silicates and / or carbonates. In some embodiments, the abrasive slurry comprises olivine, wollastonite, serpentine, and / or steel slag. In some embodiments, the abrasive slurry comprises water. In some embodiments, the slurry comprises additives. In some embodiments, the slurry optionally comprises 0-10% by weight of additives. In some embodiments, the additives are selected from sodium bicarbonate, ascorbic acid, oxalic acid, or combinations thereof. In some embodiments, the abrasive slurry comprises 10-45% by weight, or 15-40% by weight, of the olivine, wollastonite, serpentine, and / or steel slag, 0-10% by weight of additives, and water, wherein the weight percentage is relative to the total weight of the abrasive slurry. The abrasive slurry may further comprise dissolved substances, such as magnesium or calcium ions, and carbonate ions. The olivine, wollastonite, serpentine, and / or steel slag exist as solid particles. These minerals contain one or more (metallic) silicates and, upon reaction with carbon dioxide, contain one or more carbonates. When minerals such as olivine are exposed to air and water, some metallic carbonates may already be present in the mined minerals.

[0014] Embodiments of this disclosure may include reaction conditions. In some embodiments, the temperature of the countercurrent reactor is in the range of 100°C to 250°C. In some embodiments, the pressure of the countercurrent reactor is between 50 and 130 bar.

[0015] These conditions increase the reaction yield. For some fluids, these are the conditions that make them supercritical, such as supercritical carbon dioxide.

[0016] In some embodiments, the reaction between the fluid and the abrasive slurry is exothermic.

[0017] In some embodiments, the method may include the steps of: allowing at least a portion of the abrasive slurry to flow from the slurry outlet of the countercurrent reactor to a heat exchanger configured to cool the abrasive slurry, and allowing the abrasive slurry to flow from the heat exchanger through the slurry inlet into the countercurrent reactor, wherein the heat exchanger is arranged outside the countercurrent reactor. It should be understood that the remaining portion of the abrasive slurry not directed to the heat exchanger may be removed from the reactor, or more generally from the circulating slurry, and further processed, e.g., dried, to form a product material. A certain amount of unreacted abrasive slurry is added to compensate for the removed remaining portion of the abrasive slurry and allows it to mix with at least a portion of the abrasive slurry flowing toward or from the heat exchanger, and flow into the countercurrent reactor to react with the fluid. The amount of unreacted abrasive slurry added is preferably equal to the amount of the remaining slurry removed, so as to keep the slurry level in the reactor substantially constant, where “substantially” means that the slurry level is allowed to vary by up to 20%, or up to 10%, or even up to 5% relative to the total length of the reactor.

[0018] One way to achieve a substantially constant slurry level in the reactor is by using one or more suitable flow controllers or controllable valves arranged to control the flow rate of the remaining abrasive slurry, the added unreacted abrasive slurry, or both.

[0019] In some embodiments, the slurry inlet is arranged such that the abrasive slurry is introduced into the countercurrent reactor at a slurry inlet level. In some embodiments, the slurry inlet level may be equal to, higher than, or slightly higher than (e.g., up to 10 cm) the slurry level. Alternatively, the slurry inlet level may be lower than or slightly lower than (e.g., up to 10 cm) the slurry level.

[0020] In some embodiments, the slurry inlet may be the end of a slurry inlet pipe through which the abrasive slurry can flow, wherein the slurry inlet pipe extends into the reactor. The slurry inlet pipe may extend into the reactor from the side to the side or from the longitudinal end of the reactor. Optionally, the pipe may extend from a second side of the reactor. In some embodiments, the slurry inlet may be oriented downwards, with its normal direction at an angle of less than 90° relative to the central axis. In some embodiments, the normal of the slurry inlet is parallel to the central axis. In other embodiments, the normal of the slurry inlet has an angle of at least 45° relative to the central axis. The angle may be between 80° and 100°, for example, 90° (where the normal of the slurry inlet is perpendicular to the central axis).

[0021] In some embodiments, the reactor may include a slurry receiving surface or a splash guard arranged to receive any abrasive slurry flowing in a direction other than toward the second side of the reactor. This could be abrasive slurry droplets that, if not treated in this way, would cause, for example, abrasion of the reactor walls. The slurry receiving surface is arranged such that the abrasive slurry is directed toward the second side of the reactor. The slurry receiving surface may direct most or all of the flow of abrasive slurry flowing toward the first slurry inlet toward the second side of the reactor. In other words, toward the abrasive slurry in the reactor. When the slurry inlet is oriented in a downward direction, the splash guard may be positioned around the slurry inlet, for example having a tapered shape that expands toward the second side of the reactor, to receive any slurry splashed upward toward other parts of the reactor (e.g., the walls). This allows for reduced abrasion of other parts of the reactor (e.g., the reactor walls).

[0022] When most of the slurry flow contacts the slurry receiving surface, this can further aid the reaction by crushing particles in the slurry to create a larger surface area for carbon dioxide to react with substances in the particles that are reactive with carbon dioxide. In embodiments where most or all of the slurry flow is received by the slurry receiving surface, for example when the normal to the slurry inlet is perpendicular to the central axis, the slurry receiving surface can be positioned such that the slurry is at least partially or entirely guided in a downward direction parallel to the central axis toward and below the slurry level. This protects the walls and can also cause mixing eddies / mixed flows within the slurry in the reactor, thereby aiding the reaction.

[0023] The splash-proof surface is preferably made of abrasion-resistant materials, such as hardened steel (e.g., AR400 or AR500), stainless steel (e.g., duplex stainless steel, 301, 201, 431, NITRONIC 30 or NITRONIC 60 stainless steel), ceramics (e.g., alumina, silicon nitride, sialon, silicon carbide, boron carbide or zirconium oxide), and metal carbides (e.g., tungsten carbide or titanium carbide). The splash-proof surface may optionally be incorporated into the splash guard. Such a splash guard may optionally be made entirely of abrasion-resistant materials.

[0024] The use of a heat exchanger allows for control of the temperature of the abrasive slurry, and internal countercurrent reactor features (e.g., piping containing coolant) are redundant. By avoiding these internal features, wear on the countercurrent reactor is reduced. In other words, the countercurrent reactor is essentially empty when not in use. When in use, a relatively small surface area comes into contact with the flowing abrasive slurry. In this embodiment, the countercurrent reactor includes an inner wall defining the internal reactor volume, wherein at least 85%, preferably 90%, of the volume below the slurry level is arranged to receive the abrasive slurry and / or fluid, such as carbon dioxide.

[0025] In some embodiments, the heat exchanger includes one or more elongated sections arranged generally vertically, wherein the elongated sections are cooled by a coolant, and wherein the method includes the step of allowing the abrasive slurry to flow through the elongated sections.

[0026] This prevents solids from settling in the heat exchanger, and the roughly vertical arrangement improves space utilization in the production facility.

[0027] In some embodiments, the method includes the steps of: agitating at least a portion of the abrasive slurry flowing from the slurry outlet of the countercurrent reactor using a stirring device, and allowing the agitated abrasive slurry to flow toward the slurry inlet.

[0028] This disrupts the possible passivation layer on the particle surface of the abrasive slurry and increases the reaction yield.

[0029] In some embodiments, the abrasive slurry is allowed to flow downwards, and the fluid is allowed to flow upwards inside the countercurrent reactor.

[0030] This further prevents solids from settling inside the countercurrent reactor. This further helps to limit the volume of fluid contained, thereby reducing wear on the countercurrent reactor system.

[0031] In some embodiments, the fluid inlet is a nozzle located on the first side of the countercurrent reactor, and the method includes introducing the fluid in a downward direction through the fluid inlet and allowing at least a portion of the fluid to flow in an upward direction.

[0032] This maximizes the duration of fluid contact with the abrasive slurry. Furthermore, because the fluid is allowed to react with the abrasive slurry, the portion of the fluid permitted to flow upwards is smaller than the portion introduced downwards, thus generating a net downward force acting on the abrasive slurry. This net downward force promotes the flow of the abrasive slurry and reduces the input energy required to make it flow.

[0033] In some embodiments, the countercurrent reactor further includes a fluid outlet located on the first side, wherein the slurry inlet is spaced apart from the fluid outlet in a direction toward the second side of the countercurrent reactor, the method comprising allowing unreacted fluid to flow out of the countercurrent reactor through the fluid outlet and reintroducing at least a portion of the fluid flowing out of the fluid outlet into the countercurrent reactor through the fluid inlet.

[0034] This allows excess fluid to be reused and increases yield.

[0035] In some embodiments, the countercurrent reactor includes a plurality of fluid inlets, and the method includes introducing the fluid into the countercurrent reactor through each of the plurality of fluid inlets.

[0036] Multiple fluid inlets facilitate the exposure of abrasive slurry particles to the fluid, the dissolution of the fluid within the abrasive slurry, the suspension of solids, and the reduction of settling within the countercurrent reactor. Furthermore, this limits the volume of fluid contained within the slurry, as the flow of the fluid can be controlled, resulting in better overall control of the fluid-containing volume.

[0037] In some embodiments, the fluid inlet is located at different distances between the first and second sides of the countercurrent reactor.

[0038] Fluid inlets positioned at varying distances create a more stable fluid content across the entire reactor volume. Since the fluid is consumed through reaction with the abrasive slurry, multiple fluid inlets positioned at different distances between the first and second sides enable a smaller concentration gradient. This further facilitates the exposure of abrasive slurry particles to the fluid, fluid dissolution within the abrasive slurry, suspension of solids, and reduced settling within the countercurrent reactor. Furthermore, it limits the volume of fluid contained, as the fluid flow can be distributed, resulting in better overall control of the fluid-containing volume.

[0039] In some embodiments, the abrasive slurry comprises silicates and / or carbonates and water, and the fluid comprises carbon dioxide, wherein the silicate and / or carbonate feed stream is at a mass ratio of 15-35% by weight relative to the total input of silicates and / or carbonates, water, and carbon dioxide into the countercurrent reactor. In some embodiments, the water feed stream is at a mass ratio of 40-75% by weight relative to the total input of silicates and / or carbonates, water, and carbon dioxide into the countercurrent reactor. In some embodiments, the carbon dioxide feed stream is at a mass ratio of 10-25% by weight relative to the total input of silicates and / or carbonates, water, and carbon dioxide into the countercurrent reactor. Input mass ratios within the above-specified ranges further improve the reaction yield.

[0040] Optionally, in some embodiments, the slurry outlet is a first slurry outlet, and the countercurrent reactor includes a second slurry outlet arranged to output slurry from the countercurrent reactor. Furthermore, the slurry inlet is a first slurry inlet, and the countercurrent reactor system includes a second slurry inlet for supplying unreacted abrasive slurry to the countercurrent reactor. This is one method for continuously adding unreacted abrasive slurry and removing reacted abrasive slurry.

[0041] Optionally, in some embodiments, the unreacted abrasive slurry comprises 40 to 90% by weight of water per weight of unreacted abrasive slurry, and 0 to 10% by weight of additives per weight of abrasive slurry.

[0042] In addition, the unreacted abrasive slurry may contain 10 to 40% by weight of metal silicate and dissolved metal ions per weight of unreacted abrasive slurry; and 0 to 55% by weight of one or more nonreacting substances per weight of the sum of metal silicate, dissolved metal ions and nonreacting substances.

[0043] The non-reactive substance may be or may contain minerals that are non-reactive to fluids, particularly carbon dioxide. The non-reactive substance may be partially soluble in water.

[0044] Such abrasive slurries improve the efficiency of the reaction between the abrasive slurry and the fluid because they have a relatively high slurry density. It is advantageous if the one or more non-reactive substances are at most 40% by weight, or at most 30% by weight, or at most 20% by weight, or even less. The higher the slurry density, the lower the total volume that needs to be processed both within the reactor system (e.g., pumping) and outside the reactor system (e.g., filtration, drying, etc.).

[0045] Optionally, in some embodiments, the metal silicate comprises magnesium silicate, and the dissolved metal ions comprise magnesium ions.

[0046] Optionally, in some embodiments, the amount of carbon dioxide in the reactor is between 20% and 60% by weight, for example, 30% to 50% by weight, relative to the total weight of carbon dioxide and abrasive slurry in the reactor. This allows for high yields of over 70% or even 80% relative to the silicate compound (e.g., magnesium silicate) reacting with olivine. Most of the carbon dioxide is present in the gaseous or supercritical phase, while when the abrasive slurry is an aqueous abrasive slurry, between 2% and 10% of the carbon dioxide in the reactor is dissolved in the abrasive slurry.

[0047] Optionally, in some embodiments, the unreacted abrasive slurry comprises particles up to 100 μm in size, for example, with an average particle size in the range of 5 to 65 μm. This further improves the efficiency of the reaction between the abrasive slurry and the fluid.

[0048] Optionally, in some embodiments, the unreacted abrasive slurry comprises olivine, wollastonite, serpentine, and / or steel slag, preferably olivine.

[0049] Optionally, in some embodiments, the abrasive slurry is an aqueous abrasive slurry containing water.

[0050] Optionally, in some embodiments, the abrasive slurry is an aqueous abrasive slurry containing 40 to 90% by weight of water per weight of abrasive slurry and 0 to 10% by weight of additives per weight of abrasive slurry.

[0051] Furthermore, the aqueous abrasive slurry comprises 10 to 40 wt% of the following per wt weight: metal silicates, metal carbonates, silica, dissolved metal ions, and one or more non-reactive substances, and 0 to 55 wt% of the sum of the metal silicates, metal carbonates, silica, dissolved metal ions, and non-reactive substances. Such an abrasive slurry improves the efficiency of the reaction between the abrasive slurry and the fluid because it has a relatively high slurry density. It is advantageous if the one or more non-reactive substances are at most 40 wt%, or at most 30 wt%, or at most 20 wt%, or even less. The higher the slurry density, the lower the total volume that needs to be processed in the reactor system (e.g., pumping) and outside the reactor system (e.g., filtration, drying, etc.).

[0052] The non-reactive substance may be or may comprise minerals that are non-reactive to fluids (particularly carbon dioxide). The non-reactive substance may be partially soluble in water. Optionally, in some examples, the metal silicate comprises magnesium silicate, the metal carbonate comprises magnesium carbonate, and the dissolved metal ions comprise magnesium ions. Optionally, in some examples, the amount of carbon dioxide in the reactor is between 10 and 25% by weight relative to the total weight of carbon dioxide and abrasive slurry in the reactor. Optionally, in some examples, the abrasive slurry comprises particles with a size between 5 and 65 μm. This further improves the efficiency of the reaction between the abrasive slurry and the fluid. Preferably, the abrasive slurry comprises particles with a size between 10 and 60 μm, more preferably between 15 and 55 μm.

[0053] In some embodiments, the abrasive slurry optionally comprises 0-10% by weight of an additive relative to the mass of the abrasive slurry. In some embodiments, the additive is selected from sodium bicarbonate, ascorbic acid, and oxalic acid. These additives can further improve the reaction yield.

[0054] In some embodiments, the input mass ratio of silicate and / or carbonate streams is 17% by weight, the input mass ratio of carbon dioxide streams is 13% by weight, and the input mass ratio of water streams is 70% by weight. In some embodiments, the silicate and / or carbonates include olivine.

[0055] In some implementations, the input mass ratio of silicate and / or carbonate streams is 32 wt%, the input mass ratio of carbon dioxide streams is 21 wt%, and the input mass ratio of water streams is 47 wt%.

[0056] In some embodiments, the countercurrent reactor extends longitudinally along a central axis and includes a first longitudinal end on the first side and a second longitudinal end on the second side.

[0057] In some embodiments, the countercurrent reactor includes a first cross-sectional area at the first side, a second cross-sectional area at the second side, and a third cross-sectional area between the first longitudinal end and the second longitudinal end, wherein the first cross-sectional area, the second cross-sectional area, and the third cross-sectional area each extend perpendicular to the central axis, and the first cross-sectional area is a first internal cross-sectional area of ​​the countercurrent reactor, the second cross-sectional area is a second internal cross-sectional area of ​​the countercurrent reactor, and the third cross-sectional area is a third internal cross-sectional area of ​​the countercurrent reactor.

[0058] In some embodiments, the first cross-sectional area is larger than the third cross-sectional area, wherein the countercurrent reactor includes a first widening section having the first cross-sectional area, the first widening section extending partially along the countercurrent reactor from the first longitudinal end toward the second longitudinal end.

[0059] A first cross-sectional area that is larger than the third cross-sectional area helps resist reactor erosion.

[0060] In some embodiments, the second cross-sectional area is larger than the third cross-sectional area, wherein the countercurrent reactor includes a second widening section having the second cross-sectional area, the second widening section extending partially along the countercurrent reactor from the second longitudinal end toward the first longitudinal end.

[0061] The second cross-sectional area, which is larger than the third, helps resist reactor erosion. The slurry flows at a lower velocity in the second widening section, allowing the fluid to rise and allowing most of the fluid to remain in the countercurrent reactor itself.

[0062] In some embodiments, the countercurrent reactor includes a first widening section and a second widening section, wherein the countercurrent reactor includes a neck having the third cross-sectional area.

[0063] A first cross-sectional area larger than the third cross-sectional area helps resist reactor erosion.

[0064] In some embodiments, the ratio of the first cross-sectional area to the third cross-sectional area is between 1.1 and 9, preferably between 1.2 and 5, and more preferably between 1.3 and 2.25.

[0065] In some embodiments, the fluid inlet is arranged to pass through the vertical wall of the countercurrent reactor.

[0066] This reduces reactor wear.

[0067] In some embodiments, one or more stirring devices are configured to stir the fluid in the countercurrent reactor.

[0068] This accelerates the dissolution of the fluid in the abrasive slurry, thereby increasing the yield.

[0069] In some embodiments, the ratio of the second cross-sectional area to the third cross-sectional area is between 1.1 and 9, preferably between 1.15 and 5, and more preferably between 1.2 and 2.25.

[0070] The ratio of the second to the third cross-sectional area within the aforementioned range further contributes to resisting erosion and increasing yield.

[0071] According to a second aspect, a countercurrent reactor system is provided for allowing an abrasive slurry to react with a fluid, wherein the countercurrent reactor system includes a countercurrent reactor, the countercurrent reactor including a slurry inlet located on a first side of the countercurrent reactor, a slurry outlet located on a second side of the countercurrent reactor opposite to the first side, and a fluid inlet configured to introduce the fluid into the countercurrent reactor, and such that, in use, at least a portion of the introduced fluid flows in the opposite direction to the flow of the abrasive slurry.

[0072] By allowing at least a portion of the fluid to flow in the opposite direction to the abrasive slurry, the particles of the abrasive slurry are exposed to the fluid, and the fluid can dissolve in the abrasive slurry, which increases the reaction rate. The method also keeps solids suspended and reduces settling within the countercurrent reactor. Furthermore, the countercurrent flow of the fluid relative to the abrasive slurry restricts the volume containing the fluid. By restricting the volume containing the fluid, wear on, for example, is reduced.

[0073] In some embodiments of this disclosure, the countercurrent reactor includes an inclined bottom.

[0074] This prevents solids from settling in the countercurrent reactor. Furthermore, it further prevents the presence of areas in the reactor without slurry flow. Additionally, the inclined bottom allows solids to be flushed out of the reactor by applying a fluid flow if and / or when slurry flow ceases.

[0075] In some embodiments, the sloping bottom includes a membrane or mesh having multiple openings forming the fluid inlet. This further improves the distribution of fluid across the cross-sectional area of ​​the countercurrent reactor, thereby providing better overall control of the volume containing the fluid.

[0076] In some embodiments, the fluid inlet includes a nozzle arranged to inject the fluid into the countercurrent reactor in a downward direction.

[0077] This maximizes the duration of fluid contact with the abrasive slurry. Furthermore, because the fluid is allowed to react with the abrasive slurry, the portion of the fluid permitted to flow upwards is smaller than the portion introduced downwards, thus generating a net downward force acting on the abrasive slurry. This net downward force promotes the flow of the abrasive slurry and reduces the input energy required to make it flow.

[0078] In some embodiments, the countercurrent reactor system is adapted to a pressure of up to 130 bar, and the countercurrent reactor is adapted to a temperature of up to 250°C.

[0079] These conditions increase the reaction yield. For some fluids, these are the conditions that make them supercritical, such as supercritical carbon dioxide.

[0080] In some embodiments, the fluid inlet is located on the second side of the countercurrent reactor.

[0081] In some embodiments, the countercurrent reactor system further includes a fluid outlet located on the first side of the countercurrent reactor, wherein the slurry inlet is spaced apart from the fluid outlet in a direction toward the second side of the countercurrent reactor, wherein the fluid outlet is fluidly connected to the fluid inlet of the countercurrent reactor.

[0082] This allows excess fluid to be reused and increases yield.

[0083] In some implementations, the countercurrent reactor system includes multiple fluid inlets.

[0084] This further facilitates the exposure of abrasive slurry particles to the fluid, the dissolution of the fluid within the abrasive slurry, the suspension of solids, and reduces settling within the countercurrent reactor. Furthermore, it limits the volume of fluid contained within the slurry, as the flow can be distributed, resulting in better overall control of the fluid-containing volume.

[0085] In some embodiments, the countercurrent reactor system includes a plurality of fluid inlets, wherein the fluid inlets are spaced apart from each other along the length of the countercurrent reactor.

[0086] The spaced-apart fluid inlets create a more stable fluid content across the entire reactor volume. Since the fluid is consumed through reaction with the abrasive slurry, multiple fluid inlets positioned at varying distances between the first and second sides enable a smaller concentration gradient. This further facilitates the exposure of abrasive slurry particles to the fluid, the dissolution of the fluid within the abrasive slurry, the suspension of solids, and reduces settling within the countercurrent reactor. Furthermore, it limits the volume of fluid contained, as the fluid flow can be distributed, resulting in better overall control of the fluid-containing volume.

[0087] In some embodiments, the countercurrent reactor system includes one or more agitators configured to agitate the abrasive slurry and / or the fluid.

[0088] This improves the reaction yield by allowing the particles of the abrasive slurry to be exposed to the fluid, the fluid to dissolve in the abrasive slurry, keeping the solids suspended and reducing settling in the countercurrent reactor, and disrupting any passivation layer on the abrasive slurry particles.

[0089] In some embodiments, the countercurrent reactor system includes one or more agitators configured to agitate the fluid in the countercurrent reactor. The agitators may be configured to use ultrasound to agitate the fluid in the countercurrent reactor for this purpose.

[0090] This accelerates the dissolution of the fluid in the abrasive slurry, thereby increasing the yield.

[0091] In some embodiments, the countercurrent reactor system includes one or more agitators arranged outside the countercurrent reactor and configured to agitate the slurry.

[0092] This disrupts any passivation layer that may be present on the surface of the abrasive slurry particles and increases the reaction yield.

[0093] In some embodiments, the countercurrent reaction system includes a heat exchanger, wherein the heat exchanger is external to the countercurrent reactor and in fluid communication with the slurry outlet.

[0094] This allows for control of the temperature of the abrasive slurry, and internal countercurrent reactor features, such as piping containing coolant, are redundant. By avoiding these internal features, wear on the countercurrent reactor is reduced.

[0095] In some embodiments, the heat exchanger includes one or more elongated sections that are arranged generally vertically when the heat exchanger is in use and are configured to allow the abrasive slurry to flow through the elongated sections and be cooled by a coolant.

[0096] This prevents solids from settling in the heat exchanger, and the roughly vertical arrangement improves space utilization in the production facility.

[0097] In some embodiments, the fluid inlet is arranged to pass through the vertical wall of the countercurrent reactor.

[0098] This reduces wear on the countercurrent reactor.

[0099] In some embodiments, the countercurrent reactor extends longitudinally along a central axis and includes a first longitudinal end on the first side and a second longitudinal end on the second side.

[0100] In some embodiments, the countercurrent reactor includes a first cross-sectional area at the first side, a second cross-sectional area at the second side, and a third cross-sectional area between the first longitudinal end and the second longitudinal end, wherein the first cross-sectional area, the second cross-sectional area, and the third cross-sectional area each extend perpendicular to the central axis, and the first cross-sectional area is a first internal cross-sectional area of ​​the countercurrent reactor, the second cross-sectional area is a second internal cross-sectional area of ​​the countercurrent reactor, and the third cross-sectional area is a third internal cross-sectional area of ​​the countercurrent reactor.

[0101] In some embodiments, the first cross-sectional area is larger than the third cross-sectional area, wherein the countercurrent reactor includes a first widening section having the first cross-sectional area, the first widening section extending partially along the countercurrent reactor from the first longitudinal end toward the second longitudinal end.

[0102] A first cross-sectional area that is larger than the third cross-sectional area helps resist reactor erosion.

[0103] In some embodiments, the second cross-sectional area is larger than the third cross-sectional area, wherein the countercurrent reactor includes a second widening section having the second cross-sectional area, the second widening section extending partially along the countercurrent reactor from the second longitudinal end toward the first longitudinal end.

[0104] A second cross-sectional area larger than the third cross-sectional area helps resist reactor erosion.

[0105] In some embodiments, the countercurrent reactor includes a first widening section and a second widening section, wherein the countercurrent reactor includes a neck having the third cross-sectional area.

[0106] A first cross-sectional area larger than the third cross-sectional area helps resist reactor erosion. A second cross-sectional area larger than the third cross-sectional area helps resist reactor erosion.

[0107] In some embodiments, the ratio of the first cross-sectional area to the third cross-sectional area is between 1.1 and 9, preferably between 1.2 and 5, and more preferably between 1.3 and 2.25.

[0108] In some embodiments, the ratio of the second cross-sectional area to the third cross-sectional area is between 1.1 and 9, preferably between 1.15 and 5, and more preferably between 1.2 and 2.25.

[0109] This further helps resist reactor erosion. Attached Figure Description

[0110] The accompanying drawings are used to illustrate a currently preferred, non-limiting exemplary embodiment of the device of this disclosure. The foregoing and other advantages of the features and objectives of this disclosure will become more apparent, and aspects and embodiments will be better understood, by reading the following detailed description in conjunction with the accompanying drawings, in which:

[0111] Figure 1 This is a schematic diagram of a countercurrent reactor according to some embodiments of this disclosure.

[0112] Figure 2 This is a schematic diagram of a countercurrent reactor system according to some embodiments of this disclosure.

[0113] Figure 3 This is a schematic diagram of a countercurrent reactor system according to some embodiments of this disclosure.

[0114] Figure 4 This is a schematic diagram of a countercurrent reactor according to some embodiments of this disclosure.

[0115] Figure 5 This is a schematic diagram of a countercurrent reactor according to some embodiments of this disclosure.

[0116] Figure 6 This is a schematic diagram of a countercurrent reactor according to some embodiments of this disclosure.

[0117] Figure 7 This is a schematic diagram of a countercurrent reactor according to some embodiments of this disclosure.

[0118] Figure 8 This is a schematic diagram of a countercurrent reactor according to some embodiments of this disclosure.

[0119] Figure 9 This is a schematic diagram of a countercurrent reactor according to some embodiments of this disclosure.

[0120] Figure 10 This is a schematic diagram of a countercurrent reactor system according to some embodiments of this disclosure.

[0121] Figure 11 This is a schematic diagram of a countercurrent reactor according to some embodiments of this disclosure.

[0122] Figure 12 This is a schematic diagram of a countercurrent reactor according to some embodiments of this disclosure.

[0123] Figure 13 This is a schematic diagram of a countercurrent reactor according to some embodiments of this disclosure.

[0124] Figure 14 This is a schematic diagram of a countercurrent reactor according to some embodiments of this disclosure.

[0125] Figure 15 This is a schematic diagram of a countercurrent reactor system according to some embodiments of this disclosure.

[0126] Figure 16 This is a schematic diagram of a countercurrent reactor system according to some embodiments of this disclosure.

[0127] Figure 17 This is a schematic diagram of a countercurrent reactor according to some embodiments of this disclosure. Detailed Implementation

[0128] Figure 1 This is a schematic diagram of a countercurrent reactor 100 according to some embodiments of the present disclosure. In some embodiments, the countercurrent reactor 100 includes a slurry inlet 120 located at a first side 105 of the countercurrent reactor 100, a slurry outlet 130 located at a second side 110 of the countercurrent reactor 100 opposite to the first side 105, and a fluid inlet 140. Figure 1 In one embodiment, the fluid inlet 140 is depicted as a distributor. The distributor includes multiple fluid openings from which fluid, such as carbon dioxide, is released in the form of bubbles. Figure 1 In one embodiment, the fluid opening points downwards, i.e., parallel to the slurry flow direction. This advantageously reduces distributor clogging. The countercurrent reactor system according to this disclosure includes a countercurrent reactor 100 for allowing the abrasive slurry 150 to react with the fluid 155.

[0129] In some embodiments, the temperature of the countercurrent reactor 100 is in the range of 100°C to 250°C. In some embodiments, the pressure of the countercurrent reactor 100 is between 50 and 130 bar.

[0130] These conditions increase the reaction yield. For certain fluids (155), these are the conditions that make them supercritical, such as supercritical carbon dioxide.

[0131] In some implementations, the reaction between fluid 155 and abrasive slurry 150 is exothermic.

[0132] In some embodiments, the countercurrent reactor 100 includes a fluid outlet 180.

[0133] In some embodiments, the countercurrent reactor 100 extends longitudinally along a central axis 137 and includes a first longitudinal end 106 at a first side 105 and a second longitudinal end 111 at a second side 110.

[0134] In some embodiments, the countercurrent reactor 100 includes a first cross-sectional area 161 at a first side 105, a second cross-sectional area 162 at a second side 110, and a third cross-sectional area 163 between a first longitudinal end 106 and a second longitudinal end 111, wherein the first cross-sectional area 161, the second cross-sectional area 162 and the third cross-sectional area 163 each extend perpendicular to the central axis 137, and the first cross-sectional area 161 is the first internal cross-sectional area of ​​the countercurrent reactor, the second cross-sectional area 162 is the second internal cross-sectional area of ​​the countercurrent reactor, and the third cross-sectional area 163 is the third internal cross-sectional area of ​​the countercurrent reactor.

[0135] If a cylindrical reactor as shown in the figure is used, each internal cross-sectional area has an associated first inner diameter 161, second inner diameter 162, and third inner diameter 163.

[0136] In some embodiments, the slurry inlet 120 is located below the maximum slurry level 151 in the countercurrent reactor 100.

[0137] Figure 2 This is a schematic diagram of a countercurrent reactor system 20 including a countercurrent reactor 100 according to some embodiments of the present disclosure. In some embodiments, the countercurrent reactor 100 includes a slurry inlet 120 located at a first side 105 of the countercurrent reactor 100, a slurry outlet 130 located at a second side 110 of the countercurrent reactor 100 opposite to the first side 105, and a fluid inlet 140. The countercurrent reactor system according to the present disclosure includes a countercurrent reactor 100 for allowing an abrasive slurry 150 to react with a fluid 155. In some embodiments, the countercurrent reactor system includes a heat exchanger 260 configured to cool the abrasive slurry 150. The heat exchanger 260 is external to the countercurrent reactor 100. Furthermore, in some embodiments, the heat exchanger 260 includes an elongated section 261 which is arranged generally vertically during use of the heat exchanger 260 and is arranged to allow the abrasive slurry 150 to flow through the elongated section 261 and be cooled by a coolant 262. In some implementations, a pump 270 is used to induce the flow of slurry 150.

[0138] In some embodiments, the temperature of the countercurrent reactor 100 is in the range of 100°C to 250°C. In some embodiments, the pressure of the countercurrent reactor 100 is between 50 and 130 bar.

[0139] These conditions increase the reaction yield. For certain fluids (155), these are the conditions that make them supercritical, such as supercritical carbon dioxide.

[0140] In some implementations, the reaction between fluid 155 and abrasive slurry 150 is exothermic.

[0141] In some embodiments, the countercurrent reactor 100 includes a fluid outlet 180.

[0142] Figure 3 This is a schematic diagram of a countercurrent reactor system 30 including a countercurrent reactor 100 according to some embodiments of the present disclosure. In some embodiments, the countercurrent reactor 100 includes a slurry inlet 120 located at a first side 105 of the countercurrent reactor 100, a slurry outlet 130 located at a second side 110 of the countercurrent reactor 100 opposite to the first side 105, and a fluid inlet 140. The countercurrent reactor system 30 according to the present disclosure includes a countercurrent reactor 100 for allowing an abrasive slurry 150 to react with a fluid 155. In some embodiments, the countercurrent reactor system 30 includes a heat exchanger 260 configured to cool the abrasive slurry 150. The heat exchanger 260 is external to the countercurrent reactor 100. Furthermore, in some embodiments, the heat exchanger includes an elongated section 261 arranged to allow the abrasive slurry 150 to flow through the elongated section 261 and be cooled by a coolant 262. In some embodiments, a pump 270 is used to induce the flow of the slurry 150. In some embodiments, the countercurrent reactor system 30 includes a stirring device 390. The stirring device 390 according to the invention can be a grinding device, a propeller, a turbine, a paddle mixer, a pump, or a transducer for this purpose.

[0143] In some embodiments, the temperature of the countercurrent reactor 100 is in the range of 100°C to 250°C. In some embodiments, the pressure of the countercurrent reactor 100 is between 50 and 130 bar.

[0144] These conditions increase the reaction yield. For certain fluids (155), these are the conditions that make them supercritical, such as supercritical carbon dioxide.

[0145] In some implementations, the reaction between fluid 155 and abrasive slurry 150 is exothermic.

[0146] In some embodiments, the countercurrent reactor 100 includes a fluid outlet 180.

[0147] Figure 4 This is a schematic diagram of a countercurrent reactor 400 according to some embodiments of the present disclosure. In some embodiments, the countercurrent reactor 400 includes a slurry inlet 120 located at a first side 105 of the countercurrent reactor 400, a slurry outlet 130 located at a second side 110 of the countercurrent reactor 400 opposite to the first side 105, and a fluid inlet 445. The countercurrent reactor 400 is configured to allow an abrasive slurry 150 to react with a fluid 155.

[0148] In one embodiment, the fluid inlet is a nozzle 445 located at a first side 105 of the countercurrent reactor 400, and the method includes passing through the nozzle 445 in a downward direction (e.g., Figure 4 (As indicated by the arrow in the image) introduces fluid 150 and allows at least a portion of fluid 150 to flow back in an upward direction, i.e., in the opposite direction to the flow of the abrasive slurry 150.

[0149] This increases the duration of contact between the fluid 155 and the abrasive slurry 150. Furthermore, because the fluid 155 is allowed to react with the abrasive slurry 150, the portion of the fluid 155 allowed to flow upwards is smaller than the portion introduced downwards, resulting in a net downward force acting on the abrasive slurry 150. This net downward force promotes the flow of the abrasive slurry 150 and reduces the input energy required to make the abrasive slurry 150 flow.

[0150] exist Figure 4 A nozzle is depicted in the figure, but in another embodiment of the invention, the reactor may include multiple nozzles.

[0151] In some embodiments, the temperature of the countercurrent reactor 400 is in the range of 100°C to 250°C. In some embodiments, the pressure of the countercurrent reactor 400 is between 50 and 130 bar.

[0152] These conditions increase the reaction yield. For certain fluids (155), these are the conditions that make them supercritical, such as supercritical carbon dioxide.

[0153] In some implementations, the reaction between fluid 155 and abrasive slurry 150 is exothermic.

[0154] In some implementations, the countercurrent reactor 400 includes a fluid outlet 180.

[0155] Figure 5 This is a schematic diagram of a countercurrent reactor 500 according to some embodiments of the present disclosure. In some embodiments, the countercurrent reactor 500 includes a slurry inlet 120 located at a first side 105 of the countercurrent reactor 500, a slurry outlet 130 located at a second side 110 of the countercurrent reactor 500 opposite to the first side 105, and a fluid inlet 140. The countercurrent reactor 500 is configured to allow an abrasive slurry 150 to react with a fluid 155.

[0156] In some embodiments, the countercurrent reactor system further includes a fluid outlet 180 located on a first side 105 of the countercurrent reactor 500, wherein a slurry inlet 120 is spaced apart from the fluid outlet 180 in a direction toward a second side 110 of the countercurrent reactor 500, wherein the fluid outlet 180 is in fluid connection with a fluid inlet 140 of the countercurrent reactor 500.

[0157] This allows excess fluid to be reused and increases yield. In some embodiments, at least some of the fluid 155 is extracted from the countercurrent reactor 500 through fluid outlet 180 and introduced into compressor 585, which is configured to increase the pressure of the fluid for injection through fluid inlet 140.

[0158] exist Figure 5 and Figure 17 In this embodiment, the slurry inlet 120 is arranged above the slurry level 151 in the countercurrent reactor 500. However, the slurry inlet may alternatively be arranged below or equal to the slurry level as generally described above. In embodiments of other figures, the slurry inlet 120 is generally depicted below the slurry level 151. However, in any of these embodiments, the slurry inlet may alternatively be arranged above or equal to the slurry level as generally described above.

[0159] In some embodiments, the temperature of the countercurrent reactor 500 is in the range of 100°C to 250°C. In some embodiments, the pressure of the countercurrent reactor 500 is between 50 and 130 bar.

[0160] These conditions increase the reaction yield. For certain fluids (155), these are the conditions that make them supercritical, such as supercritical carbon dioxide.

[0161] In some implementations, the reaction between fluid 155 and abrasive slurry 150 is exothermic.

[0162] Figure 6 This is a schematic diagram of a countercurrent reactor 600 according to some embodiments of the present disclosure. In some embodiments, the countercurrent reactor 600 includes a slurry inlet 120 located at a first side 105 of the countercurrent reactor 600, a slurry outlet 130 located at a second side 110 of the countercurrent reactor 600 opposite to the first side 105, and a fluid inlet 641. The countercurrent reactor 600 is configured to allow an abrasive slurry 150 to react with a fluid 155.

[0163] In some embodiments, the countercurrent reactor 600 includes a plurality of fluid inlets 641, and the method includes introducing fluid 150 into the countercurrent reactor 600 through each of the plurality of fluid inlets 641.

[0164] This further facilitates the exposure of particles of the abrasive slurry 150 to the fluid 155, the dissolution of the fluid 155 in the abrasive slurry 150, the suspension of solids, and the reduction of settling within the countercurrent reactor 600. Furthermore, it limits the volume containing the fluid 155, as the flow of the fluid 155 can be further controlled, resulting in better overall control of the volume containing the fluid 155.

[0165] In some embodiments, the fluid inlet 641 is arranged at different distances between the first side 105 and the second side 110 of the countercurrent reactor 600.

[0166] In some embodiments, the fluid inlets arranged at different distances between the first side 105 and the second side 110 of the countercurrent reactor 600 are as follows: Figure 1-3 Fluid inlets depicted in 5, 7, 8, 10 and 11.

[0167] Fluid inlets 641 positioned at varying distances create a more stable fluid content across the entire reactor volume. This further facilitates the exposure of particles of the abrasive slurry 150 to the fluid 155, the dissolution of the fluid 155 within the abrasive slurry 150, the retention of solids in suspension, and reduces settling within the countercurrent reactor 600. Furthermore, this limits the volume containing the fluid 155, as the flow of the fluid 155 can be further distributed, resulting in better overall control of the volume containing the fluid 155.

[0168] In some embodiments, the temperature of the countercurrent reactor 600 is in the range of 100°C to 250°C. In some embodiments, the pressure of the countercurrent reactor 600 is between 50 and 130 bar.

[0169] These conditions increase the reaction yield. For certain fluids (155), these are the conditions that make them supercritical, such as supercritical carbon dioxide.

[0170] In some implementations, the reaction between fluid 155 and abrasive slurry 150 is exothermic.

[0171] In some implementations, the countercurrent reactor 600 includes a fluid outlet 180.

[0172] Figure 7 This is a schematic diagram of a countercurrent reactor 700 according to some embodiments of the present disclosure. In some embodiments, the countercurrent reactor 700 includes a slurry inlet 120 located at a first side 105 of the countercurrent reactor 700, a slurry outlet 130 located at a second side 110 of the countercurrent reactor 700 opposite to the first side 105, and a fluid inlet 140. The countercurrent reactor 700 is configured to allow an abrasive slurry 150 to react with a fluid 155.

[0173] In some embodiments, the first cross-sectional area 161 is larger than the third cross-sectional area 163, wherein the countercurrent reactor includes a first widening section 171 having the first cross-sectional area, the first widening section 171 extending partially along the countercurrent reactor 700 from the first longitudinal end 106 toward the second longitudinal end 111.

[0174] The first cross-sectional area 161, which is larger than the third cross-sectional area 163, helps to resist reactor erosion.

[0175] In some embodiments, the temperature of the countercurrent reactor 700 is in the range of 100°C to 250°C. In some embodiments, the pressure of the countercurrent reactor 700 is between 50 and 130 bar.

[0176] These conditions increase the reaction yield. For certain fluids (155), these are the conditions that make them supercritical, such as supercritical carbon dioxide.

[0177] In some implementations, the reaction between fluid 155 and abrasive slurry 150 is exothermic.

[0178] In some implementations, the countercurrent reactor 700 includes a fluid outlet 180.

[0179] Figure 8 This is a schematic diagram of a countercurrent reactor 800 according to some embodiments of the present disclosure. In some embodiments, the countercurrent reactor 800 includes a slurry inlet 120 located at a first side 105 of the countercurrent reactor 800, a slurry outlet 130 located at a second side 110 of the countercurrent reactor 800 opposite to the first side 105, and a fluid inlet 140. The countercurrent reactor 800 is configured to allow an abrasive slurry 150 to react with a fluid 155.

[0180] In some embodiments, the countercurrent reactor 800 includes a fluid inlet 842 arranged through the vertical wall of the countercurrent reactor 800. This reduces wear on the countercurrent reactor.

[0181] In some embodiments, the temperature of the countercurrent reactor 800 is in the range of 100°C to 250°C. In some embodiments, the pressure of the countercurrent reactor 800 is between 50 and 130 bar.

[0182] These conditions increase the reaction yield. For certain fluids (155), these are the conditions that make them supercritical, such as supercritical carbon dioxide.

[0183] In some implementations, the reaction between fluid 155 and abrasive slurry 150 is exothermic.

[0184] In some implementations, the countercurrent reactor 800 includes a fluid outlet 180.

[0185] Figure 9 This is a schematic diagram of a countercurrent reactor 900 according to some embodiments of the present disclosure. In some embodiments, the countercurrent reactor 900 includes a slurry inlet 120 located at a first side 105 of the countercurrent reactor 900, a slurry outlet 931 located at a second side 110 of the countercurrent reactor 900 opposite to the first side 105, and a fluid inlet 943. The countercurrent reactor 900 is configured to allow an abrasive slurry 150 to react with a fluid 155.

[0186] In some embodiments, the countercurrent reactor 900 includes a sloping bottom 999. In some embodiments, the sloping bottom includes a membrane or mesh having a plurality of openings forming a fluid inlet 943. This prevents solids from settling in the countercurrent reactor 900. This further improves the distribution of fluid across the cross-sectional area of ​​the countercurrent reactor, thereby providing better overall control of the volume containing the fluid. In some embodiments, the plurality of openings has a diameter of 0.5 mm, but those skilled in the art will recognize that openings with other diameters can be used within the scope of the invention.

[0187] In some embodiments, the temperature of the countercurrent reactor 900 is in the range of 100°C to 250°C. In some embodiments, the pressure of the countercurrent reactor 900 is between 50 and 130 bar.

[0188] These conditions increase the reaction yield. For certain fluids (155), these are the conditions that make them supercritical, such as supercritical carbon dioxide.

[0189] In some implementations, the reaction between fluid 155 and abrasive slurry 150 is exothermic.

[0190] In some implementations, the countercurrent reactor 900 includes a fluid outlet 180.

[0191] Figure 10 This is a schematic diagram of a countercurrent reactor system 90 including a countercurrent reactor 100 according to some embodiments of the present disclosure. In some embodiments, the countercurrent reactor 100 includes a slurry inlet 120 located at a first side 105 of the countercurrent reactor 100, a slurry outlet 130 located at a second side 110 of the countercurrent reactor 100 opposite to the first side 105, and a fluid inlet 140. The countercurrent reactor system according to the present disclosure includes a countercurrent reactor 100 configured to allow an abrasive slurry 150 to react with a fluid 155.

[0192] In some embodiments, the countercurrent reactor system 90 further includes a fluid outlet 180 located at a first side 105 of the countercurrent reactor 100, wherein a slurry inlet 120 is spaced apart from the fluid outlet 180 in a direction toward a second side 110 of the countercurrent reactor 100, wherein the fluid outlet 180 is in fluid connection with a fluid inlet 140 of the countercurrent reactor 100.

[0193] This allows excess fluid to be reused and increases yield. In some embodiments, at least some of the fluid 155 is extracted from the countercurrent reactor 100 through fluid outlet 180 and introduced into compressor 585, which is configured to increase the pressure of the fluid for injection through fluid inlet 140.

[0194] In some embodiments, the countercurrent reactor system 90 further includes a heat exchanger 260 configured to cool the abrasive slurry 150. The heat exchanger 260 is external to the countercurrent reactor 100. Furthermore, in some embodiments, the heat exchanger includes an elongated section 261. In some embodiments, a pump 270 is used to induce the flow of the slurry 150. Additionally, in some embodiments, the heat exchanger 260 includes an elongated section 261 that is arranged generally vertically during operation and is configured to allow the abrasive slurry 150 to flow through the elongated section 261 and be cooled by a coolant 262. In some embodiments, the countercurrent reactor system includes a stirring device 390. The stirring device 390 according to the invention can be a grinding device, propeller, turbine, paddle mixer, pump, or transducer for this purpose.

[0195] In some embodiments, the temperature of the countercurrent reactor 100 is in the range of 100°C to 250°C. In some embodiments, the pressure of the countercurrent reactor 100 is between 50 and 130 bar.

[0196] These conditions increase the reaction yield. For certain fluids (155), these are the conditions that make them supercritical, such as supercritical carbon dioxide.

[0197] In some implementations, the reaction between fluid 155 and abrasive slurry 150 is exothermic.

[0198] In some embodiments, the countercurrent reactor 100 includes a fluid outlet 180.

[0199] Figure 11This is a schematic diagram of a countercurrent reactor 1100 according to some embodiments of the present disclosure. In some embodiments, the countercurrent reactor 1100 includes a slurry inlet 120 located at a first side 105 of the countercurrent reactor 1100, a slurry outlet 130 located at a second side 110 of the countercurrent reactor 1100 opposite to the first side 105, and a fluid inlet 140. The countercurrent reactor 1100 is configured to allow an abrasive slurry 150 to react with a fluid 155.

[0200] In some embodiments, the countercurrent reactor 1100 includes one or more agitators 1195 configured to agitate the fluid 155 in the countercurrent reactor 1100. The agitator 1195 may be configured to agitate the fluid 155 in the countercurrent reactor for this purpose using ultrasound, which may be induced using a transducer.

[0201] In some embodiments, the temperature of the countercurrent reactor 1100 is in the range of 100°C to 250°C. In some embodiments, the pressure of the countercurrent reactor 1100 is between 50 and 130 bar.

[0202] These conditions increase the reaction yield. For certain fluids (155), these are the conditions that make them supercritical, such as supercritical carbon dioxide.

[0203] In some implementations, the reaction between fluid 155 and abrasive slurry 150 is exothermic.

[0204] In some embodiments, the countercurrent reactor 1100 includes a fluid outlet 180.

[0205] Figure 12 This is a schematic diagram of a countercurrent reactor 1200 according to some embodiments of the present disclosure. In some embodiments, the second cross-sectional area 162 is larger than the third cross-sectional area 163, wherein the countercurrent reactor includes a second widening section 172 having the second cross-sectional area 162, the second widening section 172 extending partially along the countercurrent reactor 1200 from the second longitudinal end 111 toward the first longitudinal end 106.

[0206] The second cross-sectional area 162, which is larger than the third cross-sectional area 163, helps to resist reactor erosion.

[0207] Figure 13 This is a schematic diagram of a countercurrent reactor 1300 according to some embodiments of the present disclosure. In some embodiments, the countercurrent reactor 1300 includes a first widening section 171 and a second widening section 172, wherein the countercurrent reactor 1300 includes a neck 173 having a third cross-sectional area 163.

[0208] The first cross-sectional area 161, which is larger than the third cross-sectional area 163, helps to resist reactor erosion.

[0209] The second cross-sectional area 162, which is larger than the third cross-sectional area 163, helps to resist reactor erosion.

[0210] Figure 14 This is a schematic diagram of a countercurrent reactor 1300 according to some embodiments of the present disclosure. In some embodiments, slurry outlet 130 is a first slurry outlet 130, and the countercurrent reactor 100 includes a second slurry outlet 132 arranged to output slurry 150 from the countercurrent reactor 1300. Alternatively, the second slurry outlet 132 may be located in other locations, such as between the first slurry outlet 130 and the pump 270.

[0211] At any point on the second slurry outlet 132, the first slurry flow can exit through the first slurry outlet 130, and the second slurry flow can exit through the second slurry outlet 132. The second slurry flow is less than the first slurry flow. The second slurry flow can be, for example, in the range of 0.1-2.2% of the first slurry flow. For example, the second slurry flow can be 0.6% or 0.7% of the first slurry flow. Figure 14 The second slurry outlet 132 in the configuration is arranged on the countercurrent reactor 1300.

[0212] Figure 15 This is a schematic diagram of a countercurrent reactor system 40 according to some embodiments of the present disclosure. In some embodiments, slurry inlet 120 is a first slurry inlet 120, and the countercurrent reactor system 40 includes a second slurry inlet 122 for supplying unreacted abrasive slurry to the countercurrent reactor system 40. During steady-state operation of the reactor system, the flow rate of unreacted abrasive slurry supplied to the second slurry inlet 122 may be equal to the second slurry flow, such that the slurry level within the reactor 1300 remains constant, allowing for some variation, for example, 10% higher or lower. During start-up, the amount of the second slurry flow will typically be lower than during steady-state operation, for example, to fill the reactor as needed, or to allow the reaction to reach a sufficient reaction rate.

[0213] exist Figure 15 In this configuration, a second slurry inlet 122 for supplying unreacted abrasive slurry to the countercurrent reactor system 40 is positioned in fluid communication with the first slurry inlet 120, and the second slurry inlet 122 is located between the heat exchanger 260 and the countercurrent reactor 1300. In this way, the unreacted slurry further cools the slurry from the heat exchanger 260.

[0214] The second slurry inlet 122 can be located at an alternative location in the system. For example... Figure 16Another depicted alternative is that a second slurry inlet 122 for supplying unreacted abrasive slurry to the countercurrent reactor system is located between the first slurry outlet 130 and the pump 270. In this way, the cooler unreacted slurry is cooled before the slurry flowing out of the reactor 150 enters the pump 270 and heat exchanger 260. Figure 16 In this configuration, the unreacted abrasive slurry flowing through the second slurry inlet 122 can have a higher viscosity than... Figure 15 The lower pressure in the configuration reduces the maximum pressure required for the pump (not shown) to pump unreacted abrasive slurry to the second slurry inlet 122.

[0215] In some implementations, such as Figure 17 As shown, the slurry flow path 125 extends into the countercurrent reactor 200 and terminates at a first slurry inlet 121 within the countercurrent reactor 200. The flow path 125 may be formed by one or more pipes and optionally has a flange (not shown) on the reactor to allow entry into the reactor. In some embodiments, a splash guard (included here in the splash guard 123) is installed at the end of the flow path 125 at an angle relative to the flow path 125, such that at least a portion, preferably all, of the abrasive slurry 150 is guided to flow out from the first slurry inlet 121 toward a second side 110 of the countercurrent reactor 200.

[0216] The splash guard can optionally be replaceable, reducing the number of parts in the countercurrent reactor system that need to be replaced during maintenance.

[0217] In some embodiments, the splash guard includes a slurry receiving surface made of an abrasion-resistant material selected from hardened steel (such as AR400 or AR500), stainless steel (such as duplex stainless steel, 301, 201, 431, NITRONIC 30 or NITRONIC 60 stainless steel), ceramics (such as alumina, silicon nitride, siliconium, silicon carbide, boron carbide or zirconium oxide), and metal carbides (such as tungsten carbide or titanium carbide).

[0218] exist Figure 17 In this reactor, flow path 125 enters the reactor from the side. Alternatively, the flow path may enter the reactor at any other location, such as at the longitudinal end 106, or even at any location on the second side 110 of the reactor. Slurry inlet 121 is located on the first side 105 of the reactor, preferably above, equal to, or slightly below the slurry level 151, where "slightly" means, for example, at most 50 cm or at most 20 cm.

[0219] Although this disclosure has been described with reference to specific embodiments (also shown in the accompanying drawings), it will be apparent to those skilled in the art that many variations and modifications can be made within the scope of this disclosure as described in the specification and as defined by the following claims.

[0220] For example, it will be obvious to those skilled in the art that, with reference to Figure 1-15 The features described in the specific implementation plan can be compared with those in the reference. Figure 1-15 Another specific implementation describes the use of feature combinations that use and / or replace the latter's features.

Claims

1. A method for allowing an abrasive slurry to react with a fluid in a countercurrent reactor system, the countercurrent reactor system comprising a countercurrent reactor, the countercurrent reactor including a slurry inlet located on a first side of the countercurrent reactor, a slurry outlet located on a second side of the countercurrent reactor opposite to the first side, and a fluid inlet, the method comprising the steps of: i) Introducing abrasive slurry into the countercurrent reactor through the slurry inlet; ii) Introduce fluid into the countercurrent reactor through the fluid inlet; iii) Allow the abrasive slurry to flow from the slurry inlet toward the slurry outlet through the countercurrent reactor; as well as iv) Allow at least a portion of the introduced fluid to flow in the opposite direction to the flow of the abrasive slurry and to react with the abrasive slurry.

2. The method according to claim 1, wherein the fluid inlet is disposed on the second side of the countercurrent reactor.

3. The method according to claim 1 or 2, wherein The fluid is a gas or a supercritical fluid; and / or The gas or supercritical fluid is carbon dioxide.

4. The method according to claim 1, 2 or 3, wherein the abrasive slurry comprises particles with a particle size of up to 100 μm.

5. The method according to any one of claims 1 to 4, wherein the abrasive slurry comprises silicates and / or carbonates.

6. The method of claim 5, wherein the abrasive slurry comprises olivine, wollastonite, serpentine and / or steel slag.

7. The method according to any one of claims 1 to 6, wherein the abrasive slurry comprises water.

8. The method according to any one of claims 1 to 7, wherein the temperature of the countercurrent reactor is in the range of 100°C to 250°C.

9. The method according to any one of claims 1 to 8, wherein the pressure of the countercurrent reactor is between 50 and 130 bar.

10. The method according to any one of claims 1 to 9, wherein the reaction between the fluid and the abrasive slurry is exothermic.

11. The method of claim 10, comprising the following steps: At least a portion of the abrasive slurry is allowed to flow from the slurry outlet of the countercurrent reactor to a heat exchanger configured to cool the abrasive slurry, and the abrasive slurry is allowed to flow from the heat exchanger into the countercurrent reactor through the slurry inlet, wherein the heat exchanger is arranged outside the countercurrent reactor.

12. The method of claim 11, wherein the heat exchanger comprises one or more elongated sections, wherein the elongated sections are arranged generally vertically, and wherein the elongated sections are cooled by a coolant, wherein the method comprises the steps of: The slurry is allowed to flow through the elongated section.

13. The method according to any one of claims 1 to 12, comprising the following steps: At least a portion of the abrasive slurry flowing out of the slurry outlet of the countercurrent reactor is agitated using a stirring device, and the agitated abrasive slurry is allowed to flow toward the slurry inlet.

14. The method according to any one of claims 1 to 13, wherein the slurry is allowed to flow in a downward direction and the fluid is allowed to flow in an upward direction inside the countercurrent reactor.

15. The method according to any one of claims 1 to 14, wherein the fluid inlet is a nozzle located on the first side of the countercurrent reactor, and the method comprises: The fluid is introduced downward through the fluid inlet, and at least a portion of the fluid is allowed to flow upward.

16. The method of any one of claims 1 to 15, wherein the countercurrent reactor further comprises a fluid outlet located on the first side, wherein the slurry inlet is spaced apart from the fluid outlet in a direction toward the second side of the countercurrent reactor, the method comprising allowing unreacted fluid to flow out of the countercurrent reactor through the fluid outlet and reintroducing at least a portion of the fluid flowing out of the fluid outlet into the countercurrent reactor via the fluid inlet.

17. The method according to any one of claims 1 to 16, wherein the countercurrent reactor comprises a plurality of fluid inlets, the method comprising: Fluid is introduced into the countercurrent reactor through each of the plurality of fluid inlets.

18. The method of claim 17, wherein at least two fluid inlets are arranged at different distances between the first side and the second side of the countercurrent reactor.

19. The method according to any one of claims 1 to 18, wherein the abrasive slurry comprises silicates and / or carbonates and water, and wherein the fluid comprises carbon dioxide, and wherein the input mass ratio of the silicate and / or carbonate stream is 15-35 wt%, the input mass ratio of the water stream is 40-75 wt%, and the input mass ratio of the carbon dioxide stream is 10-25 wt%, wherein the input mass ratio is expressed relative to the sum of silicates and / or carbonates, water, and carbon dioxide input to the countercurrent reactor, optionally, wherein the abrasive slurry comprises 0-10 wt% of additives.

20. The method according to any one of claims 1 to 19, wherein the countercurrent reactor extends longitudinally along a central axis and includes a first longitudinal end on the first side and a second longitudinal end on the second side.

21. The method of claim 20, wherein the countercurrent reactor includes a first cross-sectional area at the first side, a second cross-sectional area at the second side, and a third cross-sectional area between the first longitudinal end and the second longitudinal end, wherein the first cross-sectional area, the second cross-sectional area, and the third cross-sectional area each extend perpendicular to the central axis, and the first cross-sectional area is a first internal cross-sectional area of ​​the countercurrent reactor, the second cross-sectional area is a second internal cross-sectional area of ​​the countercurrent reactor, and the third cross-sectional area is a third internal cross-sectional area of ​​the countercurrent reactor.

22. The method of claim 21, wherein the first cross-sectional area is larger than the third cross-sectional area, wherein the countercurrent reactor includes a first widening section having the first cross-sectional area, the first widening section extending partially along the countercurrent reactor from the first longitudinal end toward the second longitudinal end.

23. The method of claim 21, wherein the second cross-sectional area is larger than the third cross-sectional area, wherein the countercurrent reactor includes a second widening section having the second cross-sectional area, the second widening section extending partially along the countercurrent reactor from the second longitudinal end toward the first longitudinal end.

24. The method of claims 22 and 23, comprising both the first widening section and the second widening section, wherein the countercurrent reactor includes a neck section having the third cross-sectional area.

25. The method of claim 22, wherein the ratio of the first cross-sectional area to the third cross-sectional area is between 1.1 and 9, preferably between 1.2 and 5, and more preferably between 1.3 and 2.

25.

26. The method according to any one of claims 1 to 25, wherein the fluid inlet is arranged through the vertical wall of the countercurrent reactor.

27. The method according to any one of claims 1 to 26, wherein one or more stirring devices are configured to stir the fluid in the countercurrent reactor.

28. The method of claim 23, wherein the ratio of the second cross-sectional area to the third cross-sectional area is between 1.1 and 9, preferably between 1.15 and 5, and more preferably between 1.2 and 2.

25.

29. A countercurrent reactor system for allowing an abrasive slurry to react with a fluid, wherein the countercurrent reactor system includes a countercurrent reactor comprising: The reactor includes a slurry inlet located on a first side of the countercurrent reactor, a slurry outlet located on a second side of the countercurrent reactor opposite to the first side, and a fluid inlet configured to introduce fluid into the countercurrent reactor, such that, in use, at least a portion of the introduced fluid flows in the opposite direction to the flow of the abrasive slurry.

30. The countercurrent reactor system of claim 29, wherein the countercurrent reactor includes an inclined bottom.

31. The countercurrent reactor system of claim 29 or 30, wherein the fluid inlet comprises a nozzle arranged to inject the fluid into the countercurrent reactor in a downward direction.

32. The countercurrent reactor system according to any one of claims 29 to 31, wherein the countercurrent reactor system is adapted to a pressure of up to 130 bar, and wherein the countercurrent reactor is adapted to a temperature of up to 250°C.

33. The countercurrent reactor system according to any one of claims 29 to 32, wherein the fluid inlet is arranged on the second side of the countercurrent reactor.

34. The countercurrent reactor system of claim 33, wherein the countercurrent reactor further comprises a fluid outlet located on the first side of the countercurrent reactor, wherein the slurry inlet is spaced apart from the fluid outlet in a direction toward the second side of the countercurrent reactor, wherein the fluid outlet is fluidly connected to the fluid inlet of the countercurrent reactor.

35. The countercurrent reactor system according to any one of claims 29 to 33, comprising a plurality of fluid inlets.

36. The countercurrent reactor system of claim 35, wherein the fluid inlets of the plurality of fluid inlets are spaced apart from each other along the length of the countercurrent reactor.

37. The countercurrent reactor system according to any one of claims 29 to 36, comprising one or more stirring devices configured to agitate the abrasive slurry and / or the fluid.

38. The countercurrent reactor system of claim 37, wherein one of the one or more stirring devices is configured to stir the fluid in the countercurrent reactor.

39. The countercurrent reactor system of claim 37, wherein one of the one or more stirring devices is disposed outside the countercurrent reactor and configured to stir the abrasive slurry.

40. The countercurrent reactor system according to any one of claims 29 to 39, wherein the countercurrent reactor system includes a heat exchanger, wherein the heat exchanger is external to the countercurrent reactor and in fluid communication with the slurry outlet.

41. The countercurrent reactor system of claim 40, wherein the heat exchanger comprises one or more elongated sections arranged generally vertically when the heat exchanger is in use and arranged to allow the abrasive slurry to flow through the elongated sections and be cooled by a coolant.

42. The countercurrent reactor system according to any one of claims 29 to 41, wherein the fluid inlet is arranged through the vertical wall of the reactor.

43. The countercurrent reactor system according to any one of claims 29 to 42, wherein the countercurrent reactor extends longitudinally along a central axis and includes a first longitudinal end at the first side and a second longitudinal end at the second side.

44. The countercurrent reactor system of claim 43, wherein the countercurrent reactor includes a first cross-sectional area at the first side, a second cross-sectional area at the second side, and a third cross-sectional area between the first side and the second side, wherein the first cross-sectional area, the second cross-sectional area and the third cross-sectional area each extend perpendicular to the central axis, and the first cross-sectional area is a first internal cross-sectional area of ​​the countercurrent reactor, the second cross-sectional area is a second internal cross-sectional area of ​​the countercurrent reactor, and the third cross-sectional area is a third internal cross-sectional area of ​​the countercurrent reactor.

45. The countercurrent reactor system of claim 43 or 44, wherein the first cross-sectional area is larger than the third cross-sectional area, wherein the countercurrent reactor includes a first widening section having the first cross-sectional area, the first widening section extending partially along the countercurrent reactor from the first longitudinal end toward the second longitudinal end.

46. ​​The countercurrent reactor system of claim 44, wherein the second cross-sectional area is larger than the third cross-sectional area, wherein the countercurrent reactor includes a second widening section having the second cross-sectional area, the second widening section extending partially along the countercurrent reactor from the second longitudinal end toward the first longitudinal end.

47. The countercurrent reactor system according to claims 45 and 46, comprising both the first widening section and the second widening section, wherein the countercurrent reactor includes a neck section having the third cross-sectional area.

48. The countercurrent reactor system according to claim 47, wherein the ratio of the first cross-sectional area to the third cross-sectional area is between 1.1 and 9, preferably between 1.2 and 5, and more preferably between 1.3 and 2.

25.

49. The countercurrent reactor system according to claim 48, wherein the ratio of the second cross-sectional area to the third cross-sectional area is between 1.1 and 9, preferably between 1.15 and 5, and more preferably between 1.2 and 2.25.

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