An exothermic catalytic conversion reactor

Abstract

The utility model discloses a heat release catalytic conversion reaction device, through setting up the outer tube tube plate and the inner tube tube plate in the reactor shell inside, the reactor shell is in turn divided into heat exchange cavity, product collection cavity and material cavity from top to bottom, and sets up the catalytic bed in the interlayer gap between the inner tube and the outer tube, the boiler water is passed in in the heat exchange cavity, after entering the inner tube after the gas material inlet passes in the synthesis gas, and along the inner tube ascending from the upper end baffling enters the interlayer gap, and after the reaction through the catalytic bed, from the interlayer gap lower extreme enters the product collection cavity, the heat released in the reaction process can be in time through the outer tube wall transmission to the boiler water, the steam output in the heat exchange cavity is discharged from the steam export, and the liquid level height in the heat exchange cavity decides the heat exchange intensity, and the liquid level promotes the heat exchange area to expand along with, and the heat removal capacity enhances, makes it possess dynamic heat removal capacity, and effectively controls the reaction temperature. The interlayer heat partly transfers to the inner tube synthesis gas, and can preheat raw material gas.

Description

Technical Field

[0001] This utility model belongs to the technical field of high-end equipment for the catalytic conversion of syngas to prepare high-end chemicals and clean fuels, and particularly relates to an exothermic catalytic conversion reaction device. Background Technology

[0002] The catalytic conversion of syngas to produce high-end chemicals and clean fuels (including but not limited to olefins, aromatics, jet fuel, and green methanol) has been listed as a key research direction in the "China Energy Technology Revolution Innovation Action Plan (2021-2035)". However, this process faces severe technical challenges: the syngas conversion reaction releases strong exothermic heat, which is violently released within the catalyst bed, causing a series of engineering problems. Traditional tubular fixed-bed reactors, limited by their fixed heat exchange area design, cannot adapt to changes in reaction rate. In the reaction inlet region, high concentrations of reactants trigger violent exothermic reactions, with local temperatures instantly rising to over 350°C, far exceeding the optimal operating window of Fe / Co-based catalysts. The high-temperature environment promotes deep dehydrogenation reactions on the catalyst surface. Industrial operating data shows that this carbon deposition results in a catalyst lifespan of less than 90 days per pass, requiring replacement more than four times per year. More seriously, an axial temperature gradient exceeding 100°C causes excessive hydrogenation in the lower part of the bed, reducing the target olefin selectivity to 47.5% and resulting in a large amount of by-product alkanes, thus lowering economic value. The fixed heat exchange area design cannot respond to load fluctuations. Excessive heat transfer at low loads causes the outlet temperature to drop below 280°C, leading to a precipitous decrease in the reaction rate; insufficient heat transfer at high loads causes bed overheating, with local temperatures exceeding 400°C, triggering catalyst sintering and agglomeration. A novel reaction device with dynamic heat transfer capabilities is urgently needed, which is precisely the key technical problem that this invention aims to solve. Utility Model Content

[0003] (1) Technical problem to be solved: an exothermic catalytic conversion reaction device that can dynamically transfer heat and effectively control the reaction temperature.

[0004] (2) The technical solution adopted by this utility model is as follows: An exothermic catalytic conversion reactor includes a reactor shell. Several sleeve assemblies are arrayed inside the reactor shell. Each sleeve assembly includes an inner tube and an outer tube sleeved on the inner tube. A gap is provided between the inner and outer tubes. The upper end of the inner tube communicates with the gap. A catalytic bed is arranged within the gap. An outer tube sheet is arranged in the lower part of the reactor shell. The outer tube passes through and is fixed to the outer tube sheet. The lower end of the inner tube extends out of the outer tube. An inner tube sheet is arranged below the outer tube sheet inside the reactor shell. The inner tube passes through and is fixed to the inner tube sheet. The outer and inner tube sheets divide the reactor shell into a heat exchange chamber, a product collection chamber, and a material chamber from top to bottom. A water inlet is provided at the heat exchange chamber on the reactor shell. A steam outlet is provided at the top of the reactor shell. A product outlet is provided at the product collection chamber on the reactor shell. A gas inlet is provided at the material chamber on the reactor shell.

[0005] A further technical solution involves installing multiple liquid level gauge ports on the reactor shell at the heat exchange chamber.

[0006] A further technical solution is that spiral fins are provided on the outer wall of the inner tube within the interlayer gap. The spiral fins are evenly distributed along the axial and circumferential directions, with 3-6 spiral fins evenly distributed along the circumferential direction, a spiral helix angle of 20°-30°, and a thickness of 1.0-2.0mm.

[0007] A further technical solution involves a catalyst bed height of 8-18m.

[0008] A further technical solution involves an inner tube outer diameter d=25-40mm, an outer tube outer diameter d=50-80mm, and a gap of 10-15mm between the layers.

[0009] A further technical solution is to provide an expansion gap δ≥10mm between the top of the inner tube and the inner wall of the outer tube of the reactor.

[0010] (3) Due to the adoption of the above technical solution, the beneficial effects of this utility model are: by setting an outer tube sheet and an inner tube sheet inside the reactor shell, the reactor shell is divided into a heat exchange chamber, a product collection chamber and a material chamber from top to bottom. A catalytic bed is set in the interlayer gap between the inner tube and the outer tube. Boiler water is introduced into the heat exchange chamber. Synthetic gas is introduced into the gas material inlet and then enters the inner tube. It rises along the inner tube and flows from the upper end into the interlayer gap. After reacting through the catalytic bed, it enters the product collection chamber from the lower end of the interlayer gap. The heat released during the reaction can be transferred to the boiler water in time through the outer tube wall. The steam produced in the heat exchange chamber is discharged from the steam outlet.

[0011] The liquid level in the heat exchange chamber determines the heat exchange intensity. As the liquid level rises, the heat exchange area expands, enhancing the heat transfer capacity and enabling dynamic heat transfer to effectively control the reaction temperature. Part of the heat from the jacket is transferred to the syngas in the inner tube, which can preheat the feed gas.

[0012] Deep waste heat recovery: The non-wetted area in the heat exchange chamber exchanges heat with the steam phase, minimizing heat loss. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a schematic diagram of the upper part of the sleeve described in this utility model; Figure 3 This is a schematic diagram of the connection structure of the outer tube sheet and the inner tube sheet of this utility model; Figure 4 This is a schematic diagram of the connection structure of the outer tube, grating plate, and outer tube sheet described in this utility model; Figure 5 This is a schematic diagram of the structure of the grating plate described in this utility model. Detailed Implementation

[0014] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments.

[0015] like Figures 1-5 As shown. An exothermic catalytic conversion reactor includes a reactor shell 1. Several sleeve assemblies are arrayed inside the reactor shell 1. Each sleeve assembly includes an inner tube 2 and an outer tube 3 sleeved on the inner tube 2. A gap 4 is provided between the inner tube 2 and the outer tube 3. The upper end of the inner tube 2 communicates with the gap 4. A catalytic bed 5 is arranged within the gap 4. An outer tube sheet 6 is arranged in the lower part of the reactor shell 1. The outer tube 3 passes through and is fixed to the outer tube sheet 6. The lower end of the inner tube 2 extends out of the outer tube 3. An inner tube sheet 7 is arranged below the outer tube sheet 6 inside the reactor shell 1. The inner tube 2 passes through and is fixed to the inner tube sheet 7. The outer tube sheet 6 and the inner tube sheet 7 divide the reactor shell 1 from top to bottom into a heat exchange chamber 8, a product collection chamber 9, and a material chamber 10. A water inlet 11 is provided at the heat exchange chamber 8 on the reactor shell 1. A steam outlet 12 is provided at the top of the reactor shell 1. A product outlet 13 is provided at the product collection chamber 9 on the reactor shell 1. A gas material inlet 14 is provided at the material chamber 10 on the reactor shell 1. Controlling the boiler water level in heat exchange chamber 8 can control the heat exchange area (heat transfer capacity).

[0016] Multiple level gauge ports 15 are provided on the reactor shell 1 at the heat exchange chamber 8 for installing level gauges.

[0017] Spiral fins 16 are provided on the outer wall of the inner tube 2 within the interlayer gap 4. The spiral fins 16 are evenly distributed along the axial and circumferential directions, with 3-6 spiral fins evenly distributed along the circumferential direction. The spiral helix angle is 20°-30° and the thickness is 1.0-2.0mm.

[0018] The height of the catalytic bed 5 is 8-18m.

[0019] Inner tube 2 outer diameter d=25-40mm, outer tube 3 outer diameter d=50-80mm, interlayer gap 410-15mm.

[0020] In use, the working principle is as follows: Boiler water is introduced into the heat exchange chamber 8, and synthesis gas is introduced into the gas material inlet 14 and then enters the inner tube 2. It rises along the inner tube 2 and enters the interlayer gap 4 from the top. After reacting through the catalytic bed 5, it enters the product collection chamber 9 from the bottom of the interlayer gap 4. The reaction products are collected in the collection chamber between the double tube sheets. The collection chamber is connected to the cyclone separator. The heat released during the reaction is transferred to the boiler water through the wall of the outer tube 3, and the generated steam is discharged from the steam outlet.

[0021] The reactor shell 1 adopts a vertical cylindrical structure and is made of ASTM A240 347H stainless steel. The design pressure is 4.0-8.0MPa and the design temperature is 450-600℃, which meets the requirements for use in high temperature, high pressure and corrosive environments.

[0022] A split-tube array is configured, with each tube consisting of an inner tube 2 and an outer tube 3. A gap 4 is formed between the inner tube 2 and the outer tube 3, and the gap 4 is filled with catalyst to form a catalyst bed 5, which serves as the reaction chamber. Metal spiral guide fins are installed inside the chamber to ensure that the syngas passes through the reaction chamber in a spiral trajectory, achieving radial uniform distribution and maximizing reaction efficiency. Simultaneously, a 10 mm expansion gap is reserved between the top of the inner tube 2 and the inner wall of the outer tube 3 to fully accommodate the linear expansion caused by operating temperature differences, eliminating the risk of equipment damage due to inconsistent expansion and contraction between tubes. A locking nut 17 is installed at the top of the outer tube 3, and a stainless steel wire mesh 2 is fixedly covered on the top of the inner tube 2 to ensure uniform fluid distribution and prevent catalyst backflow into the inner tube, disturbing and eroding the bed. A stainless steel wire mesh 17 is installed at the bottom of the gap 4 inside the outer tube 3, and a grid plate 18 is installed on the inner tube 2 (the inner tube 2 passes through the grid plate, and the grid plate 18 is welded and fixed to the reactor shell 1 or the inner tube, and the grid plate 18 supports the stainless steel wire mesh), used to support and seal the catalyst bed. Catalytic bed 5 innovatively adopts a segmented filling strategy: the lower 20% is filled with iron-manganese-potassium-based catalyst to ensure a carbon monoxide conversion rate of over 85%; the upper 80% uses cobalt-aluminum-based catalyst to improve olefin selectivity to over 60%.

[0023] The internal structure is a double tube sheet pressure-bearing structure. The outer tube sheet 6 is welded to the outer tube 3, and the inner tube sheet 7 is welded to the inner tube 2. A sealed cavity is formed between the two tube sheets as a collection area for reaction products.

[0024] Boiler water level-driven dynamic controllability: The boiler water system changes the tube wetting area in real time through the liquid level height (adjustable range 30%-95%). For every 10% increase in liquid level, the effective heat exchange area increases by 15%. Energy recovery paths include: Main path: producing 2.0-4.0 MPa saturated steam with a dryness of ≥98% through heat exchange on the outside of the jacket; Secondary path: preheating the syngas in inner tube 2, reducing preheating energy consumption by 15%; Auxiliary path: steam heat exchange in the non-wetting zone, reducing heat loss. Temperature control adopts a cascade PID strategy: the main controller outputs a liquid level command based on the product temperature setpoint, and the secondary controller precisely controls the boiler water flow rate through regulating valves, ultimately achieving a maximum temperature difference of 28.7℃ in the catalyst bed.

[0025] Multiple safety mechanisms: Liquid level interlock system: Equipped with triple redundancy of radar level gauges, magnetic level gauges, and differential pressure transmitters. When any two level sensors detect a level <15.0%, the system shuts off the syngas feed valve within 0.5 seconds and activates a 50 m³ / h emergency water injection pump. Differential pressure gradient response: Nitrogen backflushing is triggered when the bed pressure differential exceeds 0.5 MPa; if it exceeds 0.8 MPa, the system immediately shuts down to prevent catalyst sintering risks.

[0026] The above are merely preferred embodiments of this utility model.

Claims

1. An exothermic catalytic conversion reaction apparatus, characterized in that, The reactor includes a reactor shell (1), inside which several sleeve assemblies are arranged in an array. Each sleeve assembly includes an inner tube (2) and an outer tube (3) sleeved on the inner tube (2). A gap (4) is provided between the inner tube (2) and the outer tube (3). The upper end of the inner tube (2) is connected to the gap (4). A catalyst bed (5) is arranged inside the gap (4). An outer tube sheet (6) is arranged in the lower part of the reactor shell (1). The outer tube (3) passes through the outer tube sheet (6) and is fixed thereto. The lower end of the inner tube (2) extends out of the outer tube (3). The reactor shell (1) is located below the outer tube sheet (6). An inner tube sheet (7) is provided, and an inner tube (2) passes through the inner tube sheet (7) and is fixed thereto. The outer tube sheet (6) and the inner tube sheet (7) divide the reactor shell (1) into a heat exchange chamber (8), a product collection chamber (9) and a material chamber (10) from top to bottom. A water inlet (11) is provided at the heat exchange chamber (8) on the reactor shell (1). A steam outlet (12) is provided at the top of the reactor shell (1). A product outlet (13) is provided at the product collection chamber (9) on the reactor shell (1). A gas material inlet (14) is provided at the material chamber (10) on the reactor shell (1).

2. The exothermic catalytic conversion reaction apparatus according to claim 1, characterized in that, Multiple level gauge ports (15) are provided on the reactor shell (1) at the heat exchange chamber (8).

3. The exothermic catalytic conversion reaction apparatus according to claim 1, characterized in that, The interlayer gap (4) is provided with spiral fins (16) on the outer wall of the inner tube (2). The spiral fins (16) are evenly distributed along the axial and circumferential directions. There are 3-6 spiral fins (16) evenly distributed along the circumferential direction, with a spiral helix angle of 20°-30° and a thickness of 1.0-2.0mm.

4. The exothermic catalytic conversion reaction apparatus according to claim 1, characterized in that, The height of the catalytic bed (5) is 8-18m.

5. The exothermic catalytic conversion reaction apparatus according to claim 1, characterized in that, Inner tube (2) outer diameter d=25-40mm, outer tube (3) outer diameter d=50-80mm, interlayer gap (4) 10-15mm.

6. The exothermic catalytic conversion reaction apparatus according to claim 1, characterized in that, An expansion gap δ≥10mm is provided between the top of the inner tube (2) of the reactor and the inner wall of the outer tube (3).

Images