Reaction chamber for feedstock reactor

Abstract

To provide an improved reaction chamber for a feedstock reactor.SOLUTION: A reaction chamber for a feedstock reactor includes: an outer shell defining a reaction volume and having a heat-resistant refractory; an inlet for allowing feedstock to enter the reaction volume; an outlet for allowing reaction products, which are formed as a result of decomposition of the feedstock in the reaction volume, to exit the reaction volume; and a protective liner lining an interior surface of the outer shell and comprising a compliant shock-absorbing layer.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to pyrolysis, and in particular to a reaction chamber for a feed reactor. [Background technology]

[0002] Pyrolysis is a process in which a feed gas, such as a hydrocarbon, is broken down into its constituent elements (carbon and hydrogen in the case of hydrocarbons) in the absence of oxygen. The decomposition is caused by raising the temperature of the feed gas sufficiently until the chemical bonds of the elements in the feed gas are broken.

[0003] Such pyrolysis may be accomplished, for example, by thermally contacting the feed gas with a hot fluid. For example, combustion products formed as a result of burning a combustible fuel may be mixed with the feed gas. At a sufficiently high temperature, the mixing of the hot fluid with the feed gas and the transfer of thermal energy from the hot fluid to the feed gas is sufficient to cause the feed gas to decompose. Summary of the Invention [Problem to be solved by the invention]

[0004] During operation of the feed reactor, especially over a relatively large number of reaction cycles, the reaction chamber is subjected to high temperatures and pressures that pose concerns for the delicate refractory ceramics that typically line or are otherwise contained within the reaction chamber materials. [Means for solving the problem]

[0005] According to a first aspect of the present disclosure, there is provided a reaction chamber for a feed reactor comprising: a shell defining a reaction volume and comprising a high temperature refractory material; an inlet for allowing feed to enter the reaction volume; an outlet for allowing reaction products formed as a result of decomposition of the feed in the reaction volume to exit the reaction volume; and a protective liner lining an inner surface of the shell and comprising a compliant impact absorbing layer.

[0006] The protective liner may further include a first heat resistant layer.

[0007] The first heat resistant layer may be positioned between the inner surface of the outer shell and the conformable impact absorbing layer.

[0008] The protective liner may further include a second heat resistant layer.

[0009] The first heat resistant layer may be positioned between the inner surface of the outer shell and the conformable impact absorbing layer. The conformable impact absorbing layer may be positioned between the first heat resistant layer and the second heat resistant layer.

[0010] The heat resistant refractory material can be ceramic.

[0011] The first heat resistant layer may include a metal.

[0012] The first heat resistant layer may include one or more metals selected from the group consisting of FeCr, TiZrMo, and refractory metals.

[0013] The second heat-resistant layer may include a metal.

[0014] The second heat resistant layer may include one or more metals selected from the group consisting of FeCr, TiZrMo, and refractory metals.

[0015] The conformable impact absorbing layer may include one or both of a ceramic fiber paper and a FeCrAl mesh.

[0016] According to a further aspect of the present disclosure, there is provided a method of protecting a reaction chamber of a feed reactor, comprising inserting a protective liner into the reaction chamber and lining an interior surface of the reaction chamber with the protective liner, the protective liner including a conformable impact absorbing layer.

[0017] The protective liner may further include a first heat resistant layer.

[0018] The first heat resistant layer and the conformable impact absorbing layer may be cylindrical, and the method may further comprise forming the protective liner by positioning a cylindrical conformable impact absorbing layer around a cylindrical first heat resistant layer prior to inserting the protective liner into the reaction chamber.

[0019] The step of forming the protective liner may further include positioning a cylindrical second heat resistant layer about the cylindrical conformable impact absorbing layer.

[0020] The step of forming the protective liner may include first positioning a cylindrical conformable impact absorbing layer around a cylindrical second heat resistant layer, and then positioning a cylindrical first heat resistant layer around the cylindrical conformable impact absorbing layer.

[0021] The protective liner may be resiliently biased such that after insertion into the reaction chamber, the protective liner is biased to line the interior surface of the reaction chamber.

[0022] The protective liner may have a longitudinal opening extending from a first end of the protective liner to an opposing second end of the protective liner.

[0023] The longitudinal opening may define opposing first and second edges of the protective liner, and inserting the protective liner into the reaction chamber may include spring loading the protective liner by overlapping the first and second edges of the protective liner prior to inserting the protective liner into the reaction chamber.

[0024] The protective liner may further include one or more openings therein. Lining the interior surface of the reaction chamber with the protective liner may include aligning the one or more openings with one or more nozzles extending into the reaction chamber.

[0025] This summary does not necessarily describe the entire scope of all aspects. Other aspects, features and advantages will become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments.

[0026] Next, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. [Brief description of the drawings]

[0027] [Figure 1] FIG. 1 is a schematic diagram of a feed reactor in operation according to one embodiment of the present disclosure.

[0028] [Figure 2A] FIG. 2A shows a cross-section of a reaction chamber according to one embodiment of the present disclosure.

[0029] [Figure 2B] FIG. 2B illustrates a tapered end of a heat resistant layer of a protective liner according to one embodiment of the present disclosure.

[0030] [Figure 2C] FIG. 2C illustrates a cylindrical heat resistant layer of a protective liner according to one embodiment of the present disclosure.

[0031] [Figure 3A]3A-3C show a protective liner according to an embodiment of the present disclosure. [Figure 3B] 3A-3C show a protective liner according to an embodiment of the present disclosure. [Figure 3C] 3A-3C show a protective liner according to an embodiment of the present disclosure.

[0032] [Figure 4] FIG. 4 illustrates a conformable shock absorbing material according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] The present disclosure aims to provide an improved reaction chamber for a feed reactor. Various embodiments of the present disclosure are described below, but the present disclosure is not limited to these embodiments, and variations of these embodiments may well fall within the scope of the present disclosure, which should be limited only by the appended claims.

[0034] Generally, embodiments of the present disclosure relate to methods and systems for pyrolysis of a feed gas, such as natural gas or a hydrocarbon gas (e.g., methane). Examples of such pyrolysis methods and examples of feed gas reactors that may be used for such pyrolysis are described in more detail in PCT International Publication No. WO2020 / 118417, the entire contents of which are incorporated by reference herein.

[0035] Generally, according to an embodiment of the present disclosure, a reaction chamber for a feed reactor is disclosed herein. The reaction chamber includes a shell defining a reaction volume and including a heat-resistant refractory, an inlet for allowing feedstock to enter the reaction volume, an outlet for allowing reaction products formed as a result of decomposition of the feedstock in the reaction volume to exit the reaction volume, and a protective liner lining the inner surface of the shell. The protective liner includes a conformable impact absorbing layer and may additionally include one or more heat resistant layers. For example, the protective liner may include a first heat resistant layer between the inner surface of the shell and the conformable impact absorbing layer. The protective liner may include a second heat resistant layer. The first heat resistant layer may be positioned between the inner surface of the shell and the conformable impact absorbing layer, and the conformable impact absorbing layer may be positioned between the first heat resistant layer and the second heat resistant layer.

[0036] Next, embodiments of the present disclosure will be described in detail with reference to the drawings.

[0037] Referring to FIG. 1, there is shown a schematic of one embodiment of a feedstock reactor 100 used to crack a feedstock, according to one embodiment of the present disclosure.

[0038] The reactor 100 includes a reaction chamber 21 connected to a number of combustors 18a-18d (which may be collectively referred to as combustors 18). Each combustor 18 includes a combustion chamber to which an oxidant 13a-13d (e.g., pure oxygen or air) and a fuel 15a-15d (e.g., unreacted feedstock) are supplied. Each combustor 18 further includes an igniter 11a-11b for initiating (initiating) combustion of the fuel and oxidant within the combustion chamber.

[0039] During a reaction cycle of the reactor 100, the feedstock 12 (e.g., a hydrocarbon such as methane) is fed under pressure into the reaction chamber 21. Similarly, the combustors 18a-18d are filled with a combustible gas mixture including a mixture of fuels 15a-15d and oxidizers 13a-13d. Once the reaction chamber 21 and the combustors 18 are filled with the feedstock and the combustible gas mixture, respectively, the igniters 11a-11d are activated to cause combustion of the combustible gas mixture in the combustors 18, resulting in the production of hot combustion products 17a-17d. The combustion products 17a-17d flow under pressure through nozzles 16a-16d connected to the combustors 18 and extending into the interior volume of the reaction chamber 21. The combustion products 17a-17d are discharged from the nozzles 16a-16d and mix with the feedstock in the reaction chamber 21.

[0040] Thermal energy is transferred from the combustion products 17a-17d to the feedstock as a result of the flow of the combustion products 17a-17d into the reaction chamber 21. Energy is also transferred from the hot combustion products to the feedstock through dynamic compression of the feedstock as a result of the pressure increase within the reaction chamber 21 in response to the flow of the hot pressurized combustion products into the reaction chamber 21. After a certain point, the increase in temperature of the feedstock becomes sufficient to drive (promote) the decomposition or pyrolysis of the feedstock. For example, for methane, the decomposition follows the reaction equation: CH4+ Energy → C + 2H2 The pyrolysis reaction produces reaction products 14, which are removed from the reaction chamber 21. A portion of the reaction products 14 are recycled back to the reaction chamber 21 for future reaction cycles. In the case of methane pyrolysis, the reaction products 14 may include one or more of hydrogen, nitrogen and carbon, the unwanted products may include primarily carbon dioxide, nitrogen and water, and the recycled gas mixture may include primarily unreacted natural gas, hydrogen, nitrogen and carbon monoxide.

[0041] As described above, the reaction chamber 21 defines a reaction volume and comprises an outer shell comprising a heat-resistant refractory material (e.g., ceramic) and a protective liner lining the inner surface of the outer shell and comprising a conformal impact absorbing layer (and optionally one or more heat resistant layers).

[0042] According to some embodiments, the protective liner includes a first refractory layer and a second refractory layer, each of which may be a metal layer including a refractory metal alloy such as FeCr, TiZrMo, or a refractory metal such as tungsten, molybdenum, tantalum, niobium, rhenium, hafnium, or any combination thereof. Although the first refractory layer may provide additional heat resistance to the shell (in addition to the heat resistance provided by the refractory), during cyclic operation of the source reactor 100 (i.e., as a result of repeated reaction cycles), the reaction chamber 21 is subjected to cyclic shock loads. This may damage the shell and potentially compromise the integrity of the reaction chamber 21. To provide some protection against such shock loads, the protective liner includes a conformal shock absorbing layer, which may help protect the shell from such shock loads during operation of the reactor 100. In particular, the conformable impact absorbing layer can help prevent the impact impulse from cracking the delicate high temperature refractory material contained within the outer shell.

[0043] The conformable shock absorbing layer may additionally be heat resistant to allow it to withstand the high temperatures generated during pyrolysis. Further thermal protection may be provided by a second heat resistant layer that may sandwich the conformable shock absorbing layer with the first heat resistant layer. The conformable shock absorbing layer may further be oxidation resistant (e.g., the conformable shock absorbing layer may itself be formed of one or more layers that provide oxidation resistance to the conformable shock absorbing layer).

[0044] According to some embodiments, the protective liner may include a conformable impact absorbing layer but no heat resistant layer, although including a heat resistant layer between the conformable impact absorbing layer and the shell of the reaction chamber may help prevent the conformable impact absorbing layer from adhering to the refractory of the shell during operation of the reactor.

[0045] 2A is a schematic cross-sectional view of a reaction chamber 21 according to one embodiment of the present disclosure. The reaction chamber 21 includes a cylindrical shell 33 that includes one or more heat-resistant refractory materials (such as ceramics) to provide the reaction chamber 21 with thermal resistance to the high temperatures generated during pyrolysis. One end of the reaction chamber 21 is provided with a tapered end 35 (also including a heat-resistant refractory) adjacent the cylindrical shell 33. The opposite end of the reaction chamber 21 adjacent the cylindrical shell 33 is provided with a similar tapered end (not shown).

[0046] 2B shows one example of a tapered refractory metal layer 41 that may be used to line tapered end 35. A longitudinal slit 39 extends along the length of refractory metal layer 41 and is used to provide a spring load to refractory metal layer 41 when a protective liner including refractory metal layer 41 is inserted into tapered end 35 (described in more detail below).

[0047] 2C shows an example of a cylindrical first metal refractory layer 32 that may be used to line a cylindrical shell 33. Longitudinal slits 31 extend along the length of the metal refractory layer 32 and are used to provide a spring load to the metal refractory layer 32 when a protective liner including the metal refractory layer 32 is inserted into the cylindrical shell 33 (described in more detail below). A number of holes 37 are provided in the metal refractory layer 32 to receive the injection nozzle 16 (shown diagrammatically in FIG. 1).

[0048] 3A-3C, various embodiments of a protective liner 30 used to line the outer shell 33 of the reaction chamber 21 are shown.

[0049] Figure 3A shows a cross-section of the metallic heat-resistant layer 32. As shown in Figure 2C, the metallic heat-resistant layer 32 includes a longitudinal slit 31 extending along its length.

[0050] 3B shows a cross-section of a protective liner 30 that includes a metallic heat-resistant layer 32 and a conformable impact absorbing layer 34 that inner lines the metallic heat-resistant layer 32. The conformable impact absorbing layer 34 also includes a longitudinal slit 31 extending along its length that is aligned with the longitudinal slit in the metallic heat-resistant layer 32.

[0051] 3C shows a cross-section of a protective liner 30 that includes a metallic heat resistant layer 32, a conformable impact absorbing layer 34, and another cylindrical metallic heat resistant layer 36 that lines the inside of the conformable impact absorbing layer 34. The metallic heat resistant layer 36 also includes a longitudinal slit 31 extending along its length that is aligned with the longitudinal slits in the conformable impact absorbing layer 34 and the metallic heat resistant layer 32.

[0052] The protective liner seen in FIG. 3C may be formed by first positioning a conformable impact absorbing layer 34 around a cylindrical metallic heat resistant layer 32 and then positioning a cylindrical metallic heat resistant layer 36 around the conformable impact absorbing layer 34.

[0053] FIG. 4 shows an example of a conformable shock absorbing layer 24. The conformable shock absorbing layer 24 includes one or more suitable materials, such as ceramic fiber paper or FeCrAl mesh (in the case of FIG. 4). FeCrAl mesh is generally highly resistant to oxidation and can be used continuously up to 1,400° C. Examples of ceramic fiber papers that can be used include Fiberfrax® (https: / / www.unifrax.com / product / fiberfrax-felt-products) and Kaowool® (https: / / www.hb-specialalloy.com / fecral-alloys-introduction / ).

[0054] To line the outer shell 33 of the reaction chamber 21 with the protective liner 30, the protective liner 30 may be compressed / spring loaded (thereby compressing the tube) by overlapping one side edge of the protective liner 30 adjacent the longitudinal slit 31 with the other opposing side edge. The protective liner 30 is then inserted into the reaction chamber 21 and then released to allow the protective liner 30 to be biased against the inner diameter of the outer shell 33. This spring-loaded attachment may be further enhanced by providing the protective liner 30 with a number of holes 37 (examples of which are shown in FIG. 2C ) that align with the injection nozzles 16, thereby capturing the protective liner 30 against the outer shell 33. The protective liner 30 may be free to thermally grow as required and may be manufactured in parts (in sections) to ensure that the tapered end 35 may be lined and protected as well.

[0055] When used in the claims and / or specification in conjunction with the terms "comprising" or "including," the articles "a" or "an" may mean "one," but are also consistent with the meanings of "one or more," "at least one," and "one or more than one," unless the context clearly dictates otherwise. Similarly, the word "another" may mean at least a second one, or more than one, unless the context clearly dictates otherwise.

[0056] As used herein, the terms "coupled," "coupling," or "connected" may have several different meanings depending on the context in which the terms are used. For example, as used herein, the terms "coupled," "coupling," or "connected" may indicate that two elements or devices are directly connected to each other, or that they are connected to each other via one or more intermediate elements or devices through mechanical elements, depending on the particular context. As used herein, the term "and / or" when used in connection with a list of items means any one or more of the items in the list. As used herein, the term "and / or" when used in connection with a list of items means any one or more of the items in the list.

[0057] As used herein, references to "about (a numerical value)" or "approximately (a numerical value)," as well as references to being "substantially" equal to a numerical value, mean within + / - 10% of the numerical value.

[0058] Use of language such as "at least one of X, Y, and Z," "at least one of X, Y, or Z," "at least one or more of X, Y and Z," "at least one or more of X, Y and / or Z," or "at least one of X, Y and / or Z" is intended to include both single items (e.g., only X, only Y, or only Z) and multiple items (e.g., {X and Y}, {X and Z}, {Y and Z}, or {X, Y and Z}). The phrase "at least one" and similar phrases are not intended to entail a requirement that each possible item must be present, although each possible item may be present.

[0059] Although the present disclosure has been described in relation to particular embodiments, it should be understood that the present disclosure is not limited to these embodiments, and that changes, modifications, and variations of these embodiments may be implemented by those skilled in the art without departing from the scope of the present disclosure.

[0060] Additionally, it is contemplated that any portion of any aspect or embodiment discussed herein can be implemented or combined with any portion of any other aspect or embodiment discussed herein.

Claims

1. A reaction chamber for a feed reactor, comprising: a shell defining a reaction volume and comprising a heat-resistant refractory; an inlet for allowing feedstock to enter said reaction volume; an outlet for allowing reaction products formed as a result of decomposition of the feedstock within the reaction volume to exit the reaction volume; and a protective liner lining the interior surface of the shell and including a conformable impact absorbing layer; A reaction chamber comprising:

2. The protective liner further comprises a first heat resistant layer.

2. The reaction chamber of claim 1.

3. The first heat resistant layer is positioned between the inner surface of the outer shell and the conformable impact absorbing layer.

3. The reaction chamber of claim 2.

4. The protective liner further comprises a second heat resistant layer.

3. The reaction chamber according to claim 1 or 2.

5. the first heat resistant layer is positioned between the inner surface of the outer shell and the conformable impact absorbing layer; The conformable impact absorbing layer is positioned between the first heat resistant layer and the second heat resistant layer. The reaction chamber of claim 4.

6. The heat-resistant refractory material is a ceramic. A reaction chamber according to any one of claims 1 to 5.

7. The first heat-resistant layer includes a metal.

3. The reaction chamber of claim 2.

8. The first heat-resistant layer includes one or more metals selected from the group consisting of FeCr, TiZrMo, and refractory metals. The reaction chamber of claim 7.

9. The second heat-resistant layer includes a metal. The reaction chamber of claim 4.

10. The second heat-resistant layer includes one or more metals selected from the group consisting of FeCr, TiZrMo, and refractory metals. The reaction chamber of claim 9.

11. The conformable impact absorbing layer includes one or both of a ceramic fiber paper and a FeCrAl mesh. A reaction chamber according to any one of claims 1 to 10.

12. 1. A method for protecting a reaction chamber of a feed reactor, comprising: inserting a protective liner into the reaction chamber; lining an interior surface of the reaction chamber with the protective liner; Equipped with The protective liner includes a conformable impact absorbing layer. A method comprising:

13. The protective liner further comprises a first heat resistant layer.

13. The method of claim 12.

14. the first heat resistant layer and the conformable impact absorbing layer are cylindrical; The method comprises: forming the protective liner by positioning a cylindrical conformable impact absorbing layer around a cylindrical first heat resistant layer prior to inserting the protective liner into the reaction chamber.

14. The method of claim 13 further comprising:

15. The step of forming the protective liner further includes positioning a cylindrical second heat resistant layer about the cylindrical conformable impact absorbing layer.

15. The method of claim 14.

16. The step of forming the protective liner comprises: first positioning a cylindrical conformable impact absorbing layer around a cylindrical second heat resistant layer; thereafter, positioning a cylindrical first heat resistant layer around a cylindrical conformable impact absorbing layer; 16. The method of claim 15, comprising:

17. The protective liner is resiliently biased such that after insertion into the reaction chamber, the protective liner is biased to line the interior surface of the reaction chamber.

17. A method according to any one of claims 12 to 16.

18. The protective liner has a longitudinal opening extending from a first end of the protective liner to an opposite second end of the protective liner.

18. A method according to any one of claims 12 to 17.

19. the longitudinal opening defines opposed first and second edges of the protective liner; Inserting the protective liner into the reaction chamber includes spring-loading the protective liner by overlapping the first and second edges of the protective liner prior to inserting the protective liner into the reaction chamber.

20. The method of claim 18 .

20. the protective liner further comprising one or more openings therein; Lining the interior surface of the reaction chamber with the protective liner includes aligning the one or more openings with one or more nozzles extending into the reaction chamber.

20. The method according to any one of claims 12 to 19.

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