Reactor for synthesis of methanol

Abstract

To provide a reactor that comprises robust yet flexible reactor internals that are configured to be easily accessible for maintenance and catalyst loading, facilitate improved, even distribution of catalyst, reactants, and heat, and / or provide robust structural support during construction, transportation, installation, and operation.SOLUTION: A reactor comprises a shell and at least one reactor internal component. The reactor internal component includes a tube bundle 130 comprising a plurality of tubes attached by at least one tube support plate 150 comprising at least one radial strut and at least one bracket configured to secure to at least one tube of the tube bundle. The plurality of tubes are arranged in concentric bands about a longitudinal axis of the reactor. The reactor can also include a gas inlet plate 156, a catalyst support plate 154, and a top plate.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to reactors, particularly reactors for methanol synthesis. [Background technology]

[0002] Global climate change is considered "the most pressing environmental issue of our time." NASA states that "the scientific evidence is clear that the climate system is warming." Climate change is caused by the warming effects of greenhouse gases, such as water vapor, nitrous oxide, methane, and carbon dioxide. Of these, carbon dioxide emissions are the primary cause, as global atmospheric CO2 concentrations have increased by one-third since the beginning of the Industrial Revolution. CO2 emissions are primarily due to human activities, such as the consumption of fossil fuels, which release by-products into the atmosphere.

[0003] Chemical energy storage has been explored as a solution to the problem that renewable energy sources, such as wind and solar power, are inherently intermittent and unpredictable. Because of the intermittency of wind and solar power, power grids and utilities must meet baseline electricity demands with fossil fuel-based energy sources, but integrating suddenly available wind and solar power into the grid is difficult due to the difficulty of quickly scaling down and expanding such fossil fuel-based energy sources, such as coal-fired power plants. Because many renewable energy sources are difficult to scale up as replacements for traditional fossil fuel-based power sources, high-density energy storage of renewable energy, such that the renewable energy can be stored and used when the grid can accommodate the energy, is important for addressing climate change.

[0004] Existing energy storage modalities, including thermal energy storage, compressed air energy storage, hydrogen storage, pumped hydroelectric storage, and large-scale batteries, have so far proven prohibitively expensive and / or difficult to scale. Chemical storage of renewable energy, for example in the form of electrolysis of water to produce hydrogen for combustion, fuel cell consumption, or chemical synthesis such as methanol synthesis, is a promising approach for providing sufficiently dense and stable storage of renewable energy that can be used when needed, allowing renewable energy to supply energy demand in a constant rather than intermittent manner.

[0005] Reactors used in methanol synthesis from syngas are typically limited to boiling water reactors (BWRs) due to the high heat profile of the typical reaction suite, which contains significant amounts of CO. BWRs are complex and expensive devices, but are typically required to mitigate the heat generated from the exothermic production of methanol from syngas to protect the reaction products, reactor, and catalyst.

[0006] Shell-and-tube reactors for the synthesis of methanol from CO and H using catalytic and / or exothermic reactions, for example, a suitable catalyst such as a copper and zinc oxide (Cu / ZnO)-based catalyst or other suitable catalyst, must undergo periodic maintenance, such as loading and / or removing and refilling the catalyst, removing fouling from the reactor shell, performing repairs on various components, or otherwise. The ability to access the interior of the reactor for loading catalyst, performing maintenance, and other purposes must be balanced against the need to maintain the tubes in a bundle.

[0007] Existing shell-and-tube reactor designs are difficult to scale up or down based on the needs of a particular facility, such as the desired throughput. The facility's throughput may change over time due to debottlenecking efforts, which may increase the reactor's throughput requirements. Scaling up a reactor to debottleneck a facility can be a difficult, expensive, and time-consuming endeavor, with the entire reactor, including the internals, often needing to be modified or redesigned.

[0008] This can require a significant design and engineering effort, as engineers must essentially "reinvent the wheel" when scaling up a design, considering, among other things, tube configuration and cross-sectional area, shell size and configuration, and catalyst bed volume and cross-sectional surface area. Existing shell-and-tube reactor designs and providers are not well-suited to adapting reactor designs to changing requirements in an efficient manner. If the reactor is not properly designed, uneven distribution of catalyst, reactants, and heat can occur, which can damage the catalyst and / or reactor components and reduce the efficiency of the reaction. In many cases, a runaway exothermic reaction can result in catastrophic failure of the reactor.

[0009] Furthermore, it is difficult to scale and properly manufacture feed tubes within and / or for reactors. Improperly designed, positioned, and / or manufactured feed tubes often lead to blockages, eddies, and uneven regions of reactants within the reactor, which can disadvantageously reduce reactor efficiency and throughput, as well as lead to hot spots. Hot spots in exothermic reactions are particularly dangerous and damaging to the reactor and catalyst.

[0010] Another problem in reactor design is the difficulty of measuring the temperature inside the reactor at one or more desired locations. It is difficult to properly control a process involving a reactor, particularly in high-risk applications such as exothermic reactions, without understanding the temperature profile inside the reactor, especially at different locations along the reactor body that correspond to different stages of the reaction and / or different reactor conditions.

[0011] However, thermocouple junctions, including gasket seats, can become damaged over time, leading to thermocouple junction leaks. While such leaks can be repaired, doing so requires deactivating the catalyst and replacing the gasket seat. This involves costly, potentially dangerous, and time-consuming shutdowns, catalyst deactivations, and startups, each of which incurs high costs, including significant opportunity costs. Given that the expected catalyst life is 3-5 years, such repairs represent a very costly interruption to facility operations. Furthermore, in high-pressure and / or temperature reactions involving hydrogen, the risk of leakage from flange joints is particularly high, allowing hydrogen or other reactants / products to the outside and oxygen, a catalyst poison, to the inside.

[0012] Thus, existing reactor designs incorporating multiple thermowells for providing thermocouples at different elevations along the reactor body are susceptible to significant operational interruptions due to leaking thermocouple junctions, and reactor designs that omit such thermowells to avoid interruptions lack the reactor status data necessary to properly control the reaction. Furthermore, existing thermowell configurations in reactors insert the thermocouples transversely, e.g., radially, to the flow direction into the reactor body. This disadvantageously places temperature measurements closer to the outer shell for larger reactors, which further complicates scalability of the reactor design. Furthermore, reactor designs are ill-suited to allowing thermocouples to be inserted into the reactor body without damaging the thermocouples when catalyst is present.

[0013] Existing reactor designs may include one or more nozzles for removing spent catalyst, for example, from the bottom of the reactor body. The configuration of the catalyst removal nozzles in existing reactors is not well-suited for effective and rapid removal of catalyst, requiring operators to scrape the catalyst from the reactor body.

[0014] Certain shell-and-tube and other types of reactors may have their inlet nozzles through which reactant gases are delivered through a pipe extending through the center of the reactor body. The pipe may be drilled to accommodate one or more feed tubes, each of which may be bent to connect to a pipe and then deliver reactants upward through the reactor body. Such reactor configurations are not adapted to scale to, for example, hundreds of tubes, given the precise and tube-specific adjustments that must be made to connect a pipe to each of the multiple feed tubes.

[0015] In certain reactor configurations, the inlet pipe is further utilized to support the feed tubes at different heights within the reactor body, with one or more flat bars welded and extending between the inlet pipe and one or more feed tubes. This configuration is very time-consuming to manufacture, assemble, and maintain, especially for large reactors, and it complicates the task of scaling the reactor design to meet facility requirements. Furthermore, the inlet pipe disadvantageously occupies a significant cross-sectional area that could otherwise be occupied by catalyst. While tie rods have been considered to support the feed tubes in shell-and-tube reactors, such supports occupy catalyst space and present obstacles during catalyst loading and unloading. Summary of the Invention [Problem to be solved by the invention]

[0016] From the foregoing, there exists a need for an improved reactor configured for maintaining reactor internals and managing catalyst, for scaling up or down based on facility capacity needs, for improved measurement of reactor conditions without compromising reactor integrity and maintainability, for effective removal of spent catalyst, for improved manufacturing, and for eliminating the challenges of building shell-and-tube reactors. [Means for solving the problem]

[0017] Reactor embodiments according to the present disclosure advantageously address shortcomings of existing reactor designs by providing a reactor that is scalable and / or configured for improved access and serviceability of the reactor, particularly the reactor's interior. Reactor embodiments described above can be configured to facilitate access to the reactor interior without sacrificing the strength and robustness of the reactor interior, such as a reactor tube bundle comprising one or more tubes and one or more support structures, so that the tube bundle remains intact and undamaged.

[0018] The reactor embodiments described above further comprise tube arrangements configured for easy scaling up or down based on the needs of a particular facility. While existing reactor designs do not allow tubes to be easily added to or removed from a tube bundle depending on the reactor shell shape when constructing a reactor without significant redesign work, embodiments of the present disclosure advantageously allow annular bands or other arrangements of tubes to be modularly arranged based on the required throughput of the reactor and associated facility. In such embodiments, the tube arrangements may define regular and / or repeating patterns that can simply be added to and / or removed from existing tube bundle designs when designing a reactor. This has the advantage of making debottlenecking or other design work much easier from a manufacturing standpoint and less costly.

[0019] The tube bundle arrangement further facilitates heat and reactant distribution throughout the reactor interior, particularly through the catalyst bed, without interrupting catalyst loading, which typically occurs as operators load or dump catalyst particles into and out of the reactor interior through the open top end of the reactor. The reactor and tube bundle arrangement of embodiments advantageously provides both modularity of design for improved buildability and maintenance of desired properties regarding heat and reactant distribution, while also ensuring that the catalyst particles are evenly distributed within the reactor.

[0020] The tube bundles of reactor embodiments according to the present disclosure are further configured to provide improved structural support to one or more tubes for increased robustness of the reactor during construction, transportation, and installation, as well as during operation. In embodiments, the one or more structural supports and / or one or more of the plurality of tubes are provided with an increased thickness to ensure structural support at desired locations of the tube bundle.

[0021] In embodiments, the reactor and its components are configured to facilitate easy access for maintenance of critical parts. One or more plates configured to support the tube bundles are modular so that operators can easily load catalyst to or from the reactor interior, unload catalyst, or access components inside the reactor compared to existing reactors, and components such as support plates may be welded to the interior surface of the reactor shell and prohibit access to the reactor interior components.

[0022] Reactor embodiments address the inadequacy of existing reactor designs to provide adequate flow and reactant distribution, and thus heat distribution, within the reactor and catalyst bed by providing an improved inlet nozzle and distribution mechanism configured to direct reactants into a tube bundle disposed within the reactor. In embodiments, the inlet nozzle is located near the gas introduction plate and is positioned in a flow direction that is transverse to the flow direction of the tubes in the tube bundle. A second inlet nozzle may be located at the bottom of the reactor and may be configured with a structure for evenly distributing flow into the tubes in the tube bundle. In embodiments, one or more catalyst removal nozzles are provided in an improved configuration for removing catalyst, the removal nozzles being configured with a downward angle.

[0023] The tube bundle and the plurality of tubes may be arranged such that the cross-sectional area of ​​the plurality of tubes relative to the cross-sectional area of ​​the catalyst improves for even heat and flow distribution without interfering with the structural and modular features of the tube bundle.

[0024] Embodiments of the reactor are further configured to provide for improved distribution of the catalyst, reactor interior, and reactants during the course of the reaction, thereby reducing the occurrence of blockages, eddies, and / or uneven regions of reactants within the reactor body and associated hot spots.

[0025] Reactor embodiments of the present disclosure further address shortcomings of existing reactor designs related to process control and temperature measurement. In embodiments, the reactor is configured with one or more thermowells configured to receive one or more respective thermocouples. The thermocouples can be configured to measure temperature inside the reactor at multiple locations, each using a single thermowell positioned axially or longitudinally relative to the reactor body.

[0026] An example embodiment according to the present disclosure may relate to a reactor comprising a shell defining an interior space, at least one inlet nozzle, and a tube bundle comprising one or more tubes.

[0027] Embodiments may further comprise a catalyst support plate.

[0028] Embodiments may further comprise at least one tube support plate.

[0029] Embodiments may further comprise a gas introduction plate.

[0030] The embodiment may further comprise a top plate.

[0031] The embodiment may further comprise a top plate and a tube support plate.

[0032] Embodiments may further be configured in which the shell is configured to receive at least one catalyst.

[0033] In an embodiment, at least one catalyst is a solid catalyst. Such a solid catalyst may comprise balls of a first diameter.

[0034] In an embodiment, the solid catalyst comprises balls of a second diameter.

[0035] In embodiments, the shell is configured to receive at least one solid catalyst, which may have a shape defining at least one of a pellet, a ring, a tablet, and a sphere.

[0036] In an embodiment, the catalyst support plate is configured to support a predetermined height of the solid catalyst.

[0037] In an embodiment, the catalyst support plate defines one or more openings.

[0038] In an embodiment, the one or more openings comprise a plurality of openings of a first size and a plurality of openings of a second size, the plurality of openings extending through at least a portion of a thickness of the catalyst support plate.

[0039] In an embodiment, the first size corresponds to a circumference of at least one tube of the tube bundle.

[0040] In an embodiment, the second size is smaller than the first size.

[0041] In an embodiment, the second size is a function of the thickness of the catalyst support plate.

[0042] In embodiments, the plurality of openings of the first size are defined through the catalyst support plate according to an arrangement of the plurality of tubes.

[0043] In embodiments, the gas inlet plate includes a plurality of openings defined through a thickness of the gas inlet plate.

[0044] In an embodiment, the plurality of openings are a plurality of circular openings defined through the gas introduction plate according to the arrangement of the plurality of tubes.

[0045] In embodiments, the gas introduction plate includes a second plurality of openings defined through the thickness of the gas introduction plate, the second plurality of openings having a different size and / or shape than the plurality of circular openings.

[0046] In an embodiment, the shell defines an outlet nozzle.

[0047] In an embodiment, the outlet nozzle is located on a side of the shell.

[0048] In an embodiment, the inlet nozzle is located near the bottom of the shell.

[0049] In an embodiment, the inlet nozzle is disposed transverse to the direction of flow through the shell.

[0050] In an embodiment, the inlet nozzle is positioned generally parallel to the direction of flow through the shell.

[0051] In an embodiment, the gas introduction plate is positioned near the inlet nozzle.

[0052] In an embodiment, the at least one tube support plate comprises at least one annular band.

[0053] In embodiments, the at least one annular band comprises at least one bracket configured to extend around a portion of a tube of the tube bundle.

[0054] In embodiments, the at least one bracket extends around the entire tube.

[0055] In an embodiment, the shell defines a start-up nozzle configured for delivery of a heating fluid.

[0056] In an embodiment, the reactor further comprises at least one catalyst removal nozzle.

[0057] In an embodiment, the reactor further comprises a hand hole.

[0058] In embodiments, the at least one tube support plate defines a plurality of concentric annular bands.

[0059] In embodiments, the tube bundle comprises at least one tube of a first size and at least one tube of a second size.

[0060] In an embodiment, the inlet nozzle is located below the gas introduction plate.

[0061] In an embodiment, the shell defines an outlet nozzle, and the outlet nozzle is disposed below the catalyst support plate.

[0062] In an embodiment, catalyst (e.g., balls) of a first size (e.g., diameter) and catalyst (e.g., balls) of a second size (e.g., diameter) are arranged in separate respective layers adjacent the catalyst support plate.

[0063] In an embodiment, the shell is configured to receive at least one solid catalyst, the catalyst defining a first height within the shell in an unreduced state and a second height within the shell in a reduced state (e.g., due to settling that may occur during operation).

[0064] In an embodiment, the second height is less than the first height.

[0065] In embodiments, the at least one tube support plate defines at least one radial strut connected to at least one of the plurality of annular bands.

[0066] In embodiments, the at least one radial strut connects to at least one of the plurality of annular bands and to an outer support band.

[0067] In embodiments, the innermost annular band of the at least one tube support plate includes any number (e.g., six) of brackets, each configured to correspond to a ring of an equal number of innermost tubes of a first size.

[0068] In embodiments, the second annular band of the at least one tube support plate includes an equal or greater number of brackets compared to the preceding band (e.g., 10), and the brackets of the second annular band are each configured to correspond to a concentric band (e.g., ring) of the same number of tubes of the tube bundle located within the second concentric band or ring of tubes, which may be of a first size.

[0069] In embodiments, the third annular band of the at least one tube support plate includes an equal or greater number of brackets than the preceding band (e.g., 14), and the brackets of the third annular band are each configured to correspond to a concentric band (e.g., ring) of the same number of tubes of the tube bundle located within the third concentric band or ring of tubes, which may be of a second size.

[0070] In embodiments, the fourth annular band of the at least one tube support plate includes an equal or greater number of brackets compared to the preceding band (e.g., 18), and the brackets of the fourth annular band are each configured to correspond to a concentric band (e.g., ring) of the same number of tubes of the tube bundle located within the fourth concentric band or ring of tubes, which may be of a first size.

[0071] In embodiments, the fifth annular band of the at least one tube support plate includes an equal or greater number of brackets than the preceding band (e.g., 22), and the brackets of the fifth annular band are each configured to correspond to a concentric band (e.g., ring) of a like number of tubes of the tube bundle located within the fifth concentric band or ring of tubes, which may be of a first size.

[0072] In embodiments, the sixth annular band of the at least one tube support plate includes an equal or greater number of brackets than the preceding band (e.g., 26), and the brackets of the sixth annular band are each configured to correspond to a concentric band (e.g., ring) of the same number of tubes of the tube bundle located within the sixth concentric band or ring of tubes, which may be of a first size.

[0073] In embodiments, the seventh annular band of the at least one tube support plate includes an equal or greater number of brackets compared to the number of brackets of the preceding band (e.g., 30), and the brackets of the seventh annular band are each configured to correspond to a concentric band (e.g., ring) of the same number of tubes of the tube bundle located within the seventh concentric band or ring of tubes, which may be of a second size.

[0074] In embodiments, the eighth annular band of the at least one tube support plate includes an equal or greater number of brackets than the preceding band (e.g., 34), and the brackets of the eighth annular band are each configured to correspond to a concentric band (e.g., ring) of the same number of tubes of the tube bundle located within the eighth concentric band or ring of tubes, which may be of a first size.

[0075] In embodiments, the ninth annular band of the at least one tube support plate includes an equal or greater number of brackets than the preceding band (e.g., 36), and the brackets of the ninth annular band are each configured to correspond to a concentric band (e.g., ring) of the same number of tubes of the tube bundle located within the ninth concentric band or ring of tubes, which may be of a first size.

[0076] In embodiments, a tenth annular band of the at least one tube support plate includes an equal or greater number of brackets than the preceding band (e.g., 42), and the brackets of the tenth annular band are each configured to correspond to a concentric band (e.g., ring) of the same number of tubes of the tube bundle located within the tenth concentric band or ring of tubes, which may be of a first size.

[0077] In embodiments, an eleventh annular band of the at least one tube support plate includes an equal or greater number of brackets than the preceding band (e.g., 46), and the brackets of the eleventh annular band are each configured to correspond to a concentric band (e.g., ring) of the same number of tubes of the tube bundle located within the eleventh concentric band or ring of tubes, which may be of a second size.

[0078] In embodiments, a twelfth annular band of the at least one tube support plate includes an equal or greater number of brackets than the preceding band (e.g., 50), and the brackets of the twelfth annular band are each configured to correspond to a concentric band (e.g., ring) of the same number of tubes of the tube bundle located within the twelfth concentric band or ring of tubes, which may be of a first size.

[0079] In embodiments, a thirteenth annular band of the at least one tube support plate includes an equal or greater number of brackets than the preceding band (e.g., 54), and the brackets of the thirteenth annular band are each configured to correspond to a concentric band (e.g., ring) of a like number of tubes of the tube bundle located within the thirteenth concentric band or ring of tubes, which may be of a first size.

[0080] In embodiments, a fourteenth annular band of the at least one tube support plate includes an equal or greater number of brackets than the preceding band, and the brackets of the thirteenth annular band are each configured to correspond to a concentric band (e.g., ring) of an equal number of tubes of the tube bundle located within the fourteenth concentric band or ring of tubes, which may be of a second size.

[0081] It will be apparent that any number of annular bands may be provided.

[0082] In embodiments, any of the plurality of annular bands of the at least one tube support plate further includes a bracket corresponding to at least one thermocouple insertion tube, which may be similarly sized (e.g., first or second size) to the plurality of tubes of the tube bundle.

[0083] In an embodiment, at least four tube support plates are positioned longitudinally along the tube bundle.

[0084] In an embodiment, at least one tube support plate is disposed longitudinally along the tube bundle, and the annular band of the at least one tube support plate further includes a bracket corresponding to at least one thermocouple insertion tube, the at least one thermocouple insertion tube configured to receive a temperature measurement device.

[0085] In an embodiment, the temperature measurement device is configured to obtain temperatures at a plurality of longitudinal locations within the reactor.

[0086] In embodiments, the temperature measurement device is configured to obtain temperature at multiple locations (eg, at least eight different locations), eg, longitudinally along the reactor.

[0087] In embodiments, the shell defines at least one flange to facilitate attachment and detachment between the top of the shell and the body of the shell.

[0088] In an embodiment, the shell is configured to be attached to a skirt at the bottom of the shell.

[0089] In embodiments, the skirt defines an opening configured to receive a lead-in spool.

[0090] In an embodiment, the at least one tube support plate defines at least one radial strut connected to at least one of the plurality of annular bands of the tube support plate, the at least one radial strut of the at least one tube support plate being axially aligned with at least one radial strut of another tube support plate.

[0091] In embodiments, the at least one radial strut of the at least one tube support plate is axially offset relative to the at least one radial strut of an adjacent tube support plate.

[0092] In embodiments, the at least one tube support plate defines a plurality of radial struts arranged symmetrically about the longitudinal axis of the reactor. do.

[0093] In an embodiment, the at least one tube support plate defines at least one radial strut connected to at least one of the plurality of annular bands of the tube support plate, the at least one annular band of the at least one tube support plate being removably secured to the at least one radial strut.

[0094] In an embodiment, at least one tube of the tube bundle defines a uniform thickness longitudinally within the reactor.

[0095] In an embodiment, at least one tube of the tube bundle defines a tapered thickness longitudinally within the reactor.

[0096] In embodiments, at least one tube of the tube bundle is configured to facilitate a greater degree of heat transfer near the bottom of the reactor relative to the top of the reactor.

[0097] Any of the features described above, or other features described herein, may be used in combination with each other, alone, or in combination with other features.

[0098] Other methods, embodiments, and variations of the system are described in more detail in the following description.

[0099] These and other features, aspects, and advantages of the present invention will become readily apparent and better understood in view of the following specification, appended claims, and accompanying drawings. [Brief explanation of the drawings]

[0100] [Figure 1A] FIG. 1 is a perspective view of a reactor according to an embodiment of the present disclosure. [Figure 1B] FIG. 1B is a rotated perspective view of a reactor according to the embodiment of FIG. 1A. [Figure 2] FIG. 1B is a plan view of a reactor according to the embodiment of FIG. 1A. [Figure 3] 1A is a cutaway elevation view of the reactor and reactor interior of the embodiment of FIG. 1A taken along line 1A-1A. [Figure 4] 1A is a cutaway elevation view of the reactor and catalyst bed and catalyst support layer of the embodiment of FIG. 1A taken along line 1A-1A. [Figure 5A] FIG. 1B is an enlarged cutaway elevation view of the reactor of the embodiment of FIG. 1A, with detail IV. [Figure 5B] 1B is an enlarged cutaway elevation view of the reactor of the embodiment of FIG. 1A, detail III. [Figure 6] FIG. 1B is a perspective view of a tube bundle for use with a reactor according to the embodiment of FIG. 1A. [Figure 7] FIG. 7 is an elevational view of the tube bundle of the embodiment of FIG. 6. [Figure 8] FIG. 7 is a perspective view of a tube bundle and tube support plate according to the embodiment of FIG. 6. [Figure 9] FIG. 1B is a plan view of the top and feed tube support plate according to the reactor embodiment of FIG. 1A. [Figure 10A] FIG. 7 is a plan view of the tube support plate according to the embodiment of FIG. 6. [Figure 10B] FIG. 10 is a plan view of a tube support plate according to another embodiment. [Figure 11] FIG. 1B is a plan view of a gas introduction plate according to the reactor embodiment of FIG. 1A. [Figure 12] FIG. 1B is a plan view of a catalyst support plate according to the reactor embodiment of FIG. 1A. [Figure 13] FIG. 11 is an enlarged plan view of the catalyst support plate in detail XII. [Figure 14] FIG. 1B is a perspective exploded view of the top plate and reactor according to the embodiment of FIG. 1A. [Figure 15] FIG. 15 is a plan view of the top plate of the embodiment of FIG. 14. [Figure 16] FIG. 1B is an enlarged perspective exploded view of a top plate for use with the reactor of the embodiment of FIG. 1A according to FIG. [Figure 17] 16A is an elevational cutaway view of a retainer plate for use with a nozzle of a reactor according to the embodiment of FIG. 1A taken along line 16A-16A. [Figure 18] 18 is an elevational view of the retainer plate and nozzle according to the embodiment of FIG. 17. [Figure 19] FIG. 18 is a perspective view of a retaining plate and nozzle according to the embodiment of FIG. [Figure 20] FIG. 10 is a cutaway elevation view of a reactor, catalyst bed, and thermocouple insertion tube according to another embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0101] A better understanding of the different embodiments of the present invention may be obtained from the following description read in conjunction with the accompanying drawings, in which like reference numerals represent like elements and in which:

[0102] While the present disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments have been shown in the drawings and are described below. It is to be understood, however, that there is no intention to limit the disclosure to the disclosed embodiments, but on the contrary, the intention is to cover all modifications, alternative constructions, combinations, and equivalents which fall within the spirit and scope of the disclosure and as defined by the appended claims.

[0103] Unless any term is defined in this patent to have a stated meaning, it will be understood that no intention exists to explicitly or implicitly limit the meaning of such term beyond its plain or ordinary meaning.

[0104] 1A, a reactor 100 according to an embodiment of the present disclosure is shown. The reactor 100 comprises a shell 102 defining an interior space 103 (FIG. 4) and comprising at least one inlet nozzle 120. The reactor 100 is configured to receive and cooperate with at least one reactor internal component, such as a tube bundle 130 (FIG. 3) comprising one or more tubes 131. The reactor 100 extends longitudinally from a top end 105 to a bottom end 107 about an axis 1A-1A and may define a generally cylindrical shape.

[0105] An inlet nozzle 120 is positioned near the bottom end 107 through which one or more reactants enter, travel upward in direction F1 (FIG. 4) within one or more tubes 131 through the interior space 103 of the reactor 100, and then exit the tubes 131 near the top end 105, turning downward in direction F2 to an outlet nozzle 124 defining a corresponding flange 125. As the reactants travel upward through the one or more tubes 131, they exchange heat with the catalyst and with the reactants and products traveling downward in direction F2 (FIG. 4).

[0106] For exothermic reactions, such as methanol synthesis, the reactants advantageously absorb heat generated by the reaction within the tubes 131 to preheat the reactants before feeding them to the catalyst bed 140. This further advantageously mitigates the formation of catalyst hot spots and associated catalyst sintering and product degradation. This further reduces the likelihood of runaway reactions, as the reactants define the heat exchange medium for removing heat from the catalyst bed. Due to the distribution of the tubes 131, the reactants form a much more effective heat exchange modality than, for example, a cooling water sleeve surrounding the reactor 100.

[0107] In addition to the inlet nozzle 120 and the outlet nozzle 124, the reactor 100 may define one or more catalyst removal nozzles 116 and / or one or more hand holes 118 through which the interior space 103 is accessible. The one or more catalyst removal nozzles 116 may be angled downward to facilitate gravity-based removal of catalyst from the catalyst bed 140, for example, when removing and refilling spent catalyst. The one or more hand holes 118 may facilitate maintenance by allowing a technician to insert a hand, tool, or instrument into the interior space 103 near the catalyst support plate 154, the catalyst bed 140, or any other suitable location.

[0108] 1A and 1B, reactor 100 defines a start-up nozzle 110 configured for the supply of a heated fluid. During start-up operation, if the reaction has not yet reached steady-state operation, the reactants may not receive the required amount of preheating as they travel in direction F1 within tube bundle 130. Start-up nozzle 110 may pass through interior space 103 and may receive a heated fluid, such as an inert gas like heated nitrogen gas, that provides sufficient enthalpy to achieve steady-state operation without adversely affecting the yield of the reaction.

[0109] Shell 102 may further define at least one thermocouple port 106. Each thermocouple port 106 may facilitate axial or longitudinal insertion of a temperature measurement device into reactor 100, in embodiments, into tube bundle 130. By locating thermocouple ports 106 in the top 105 of reactor 100, a single temperature measurement device, such as a thermocouple, capable of measuring temperature at multiple locations may be inserted therethrough. In embodiments, the temperature measurement device may be elongated and include multiple measurement devices, such as multiple thermocouples, spaced apart at predetermined distances such that reactor conditions at each of the predetermined distances may be measured for improved control of the reaction.

[0110] 1A and 1B, one on each side of the start-up nozzle 110, it will be understood that more or fewer thermocouple ports 106 may be provided in any suitable location. By providing temperature measurement devices via the thermocouple ports 106, the reactor 100 advantageously allows for measurement of reactor conditions at different elevations within the reactor while minimizing the number of thermocouple junctions, thereby facilitating improved process control and throughput while minimizing the risk of leakage into or out of the shell 102. The location of the thermocouple ports 106 further allows for sampling of reactor conditions at desired radial locations of the reactor 100, regardless of the size of the reactor 100, as opposed to existing reactor designs in which thermocouples are inserted radially such that larger reactors are sampled disproportionately near the shell.

[0111] 4, the shell 102 defines an inlet nozzle 120 with a corresponding flange 121 located any distance below the gas introduction plate 156, and both may be located near the bottom end 107 of the reactor 100. The inlet nozzle 120 may be positioned transverse to the longitudinal extension of the reactor 100 such that as the reactants flow through the inlet nozzle 120 in flow direction F4, they change direction and flow through the gas introduction plate 156 into one or more tubes 131 of the tube bundle 130 in direction F1.

[0112] Inlet nozzle 120 may be positioned as shown to optimize the distance between inlet nozzle 120 and the bottom of tube bundle 130 and to evenly distribute reactants to the tubes 131 to avoid blockages, hot spots, and eddies that result in uneven flow. Flanges 121 may be configured to facilitate attachment of reactant supply lines to nozzle 120. While shown and depicted for inlet nozzle 120, it will be understood that the distance between inlet nozzle 120 and the bottom of tube bundle 130 may be greater or less, as appropriate.

[0113] Additionally or alternatively, the shell 102 may further define a second inlet nozzle 132 with a corresponding flange 133, as shown in FIG. 5A. The flange 133 may be configured to facilitate attachment of a reactant supply line to the nozzle 132. The second inlet nozzle 132 is positioned to deliver reactants vertically in a direction F3 that may correspond to or be parallel to an upward flow direction F1 through the tube 131. The reactor shell 102 may be secured by a skirt 108 that may define an opening 122 through its thickness configured to receive an inlet spool 135 that connects to the second inlet nozzle 132.

[0114] The skirt 108 may be cylindrical in shape and extend downward from the bottom end 107 substantially coextensively with the reactor shell 102. The skirt 108 may define a coplanar ring 109 that secures the reactor 100 and skirt 108 in place. The inlet spool 135 may be curved so that reactants are fed into the reactor 100 in a flow direction generally transverse to the flow direction F3, e.g., generally parallel to the direction F4 of the inlet nozzle 120. The inlet nozzle 120 and the second inlet nozzle 132 may be configured to act simultaneously or independently of one another. While shown and depicted with a skirt, any suitable support may be utilized, and the present disclosure is not limited to the use of a skirt.

[0115] In embodiments, a flow diverter 137 may be removably positioned within the second inlet nozzle 132 or the shell 102 to guide the flow direction of the reactants when the second inlet nozzle 132 is in use. The flow diverter 137 may define a shape that distributes a portion of the reactant flow from the second inlet nozzle 132 radially outward such that the flow is evenly distributed among a plurality of central tubes that are generally aligned with the second inlet nozzle 132 and the plurality of outer tubes. While shown and depicted as flow diverter 137, it will be understood that any suitable structure, configuration, or arrangement may be utilized. In embodiments, the flow diverter 137 defines a plurality of openings and / or protrusions configured to distribute the reactant flow entering through the nozzle 132.

[0116] 5B, reactor 100 may further include a domed head 104 removable from shell 102 and releasably attached thereto at flanges 112, 114, which may include any suitable means for attaching domed head 104 and shell 102, such as apertures and corresponding fasteners. Domed head 104 may define a space 113 above an upper extent of tube bundle 130. Space 113 provides space for preheated reactants to mix and return downward through catalyst bed 140. Nozzle 110 may be defined through the thickness of domed head 104 to allow for the addition of heating media during start-up operations, as previously described.

[0117] Although shown and depicted with a dome-shaped head that is releasably securable to the shell, it will be understood that the disclosure is not limited thereto and that a fixed head with, for example, a flanged manhole may be utilized instead for any size reactor.

[0118] The thermocouple ports 106 may be aligned with respective thermocouple insertion tubes 126, which may extend any distance above the upper extent of the tube bundle 130. The thermocouple ports 106 may extend partially or entirely through the thickness of the domed head 104 to allow access to the reactor interior 103. The thermocouple ports 106 may facilitate access to the reactor interior 103 in any suitable manner, for example, by defining an opening sized to be flush with the surface of a temperature measurement device so that pressure can be maintained within the reactor interior 103, by cooperating with a gasket seal, a combination thereof, or any other suitable means. Any suitable means may be used. By extending any distance above the upper extent of the tube bundle 130, the thermocouple insertion tubes 126 are configured to be more easily identified during thermocouple installation, especially since access is limited when the domed head 104 is in place. The thermocouple insertion tube 126 may extend along the length of the reactor 100 generally parallel to or aligned with the feed tube 131 .

[0119] Reactor 100 includes one or more catalyst support plates 154, at least one tube support plate 162, 163, 164, 165, gas inlet plate 156, upper feed tube support plate 150, and / or upper plate 190, which may advantageously facilitate securing tube bundle 130 within shell 102 while allowing access to reactor interior 103 as needed for maintenance or other purposes. Gas inlet plate 156 and catalyst support plate 154 may advantageously be welded to the interior surface of shell 102 to secure tube bundle 130 therein.

[0120] The tubes 131 of the tube bundle 130 may be welded to the gas inlet plate 156, the upper feed tube support plate 150, and / or at least one tube support plate 162, 163, 164, 165. In embodiments, only the gas inlet plate 156 is welded or otherwise secured to the inner surface of the reactor shell 102, and the upper feed tube support plate 150 and at least one tube support plate 162, 163, 164, 165 are free to accommodate thermal expansion of the tubes 131.

[0121] Turning to Figure 4, catalyst bed 140 may comprise one or more sections of catalyst, such as a solid catalyst. Catalyst bed 140 may additionally or alternatively comprise one or more inert sections 142, 144, which may comprise supported ceramic balls of a first diameter, e.g., 1-30 mm, more specifically, 5-20 mm, or in embodiments, 9 mm. Catalyst bed 140 may further comprise supported ceramic balls of a second diameter, e.g., 1-30 mm, more specifically, 10-25 mm, or in embodiments, 19 mm. Catalyst bed 140 may define separate sections 142, 144 corresponding to the ceramic balls, substantially comprising only balls of a single size.

[0122] For example, in the depicted embodiment, section 142 comprises substantially only balls having a diameter of 9 mm, while section 144 comprises substantially only balls having a diameter of 19 mm. Sections 142, 144 may have any suitable height within reactor 100, e.g., 5 to 500 mm, more specifically 100 to 300 mm, or in embodiments, 200 mm per section 142, 144. The heights of sections 142, 144 may be the same or different from one another. Catalyst bed 140 may also, or alternatively, comprise solid catalyst having a shape defining at least one of pellets, rings, tablets, and spheres. Sections 142, 144 may be positioned adjacent to (e.g., above or directly above) catalyst support plate 154 and substantially below section 141, which comprises only solid catalyst of a different shape and / or size relative to the supporting ceramic balls of sections 142, 144.

[0123] The support ceramic ball sections 142, 144 advantageously support the weight of the catalyst within the catalyst bed while promoting effective and even flow distribution. By providing separate first and second sections 142, 144, the flow of reactants, products, and by-products through the reactor interior 103 toward the exit nozzle 124 is improved by allowing gas flow between catalyst particles in the catalyst bed 140, between the smaller, first-diameter support ceramic balls in the first section 142, and finally between the larger, second-diameter support ceramic balls in the second section 144 before passing through the catalyst support plate 154. The support ceramic balls are advantageously inert and may be configured to withstand thermal shock and corrosion from the various reactants, products, and / or by-products. While support ceramic balls are described, it will be understood that sections 142, 144 may have more or fewer sections and may comprise support structures of different shapes or sizes, such as rings, cylinders, polygons, or other.

[0124] In an embodiment, section 141 of catalyst bed 140 may have or define a first height 148 corresponding to the height of unreduced catalyst and a second height 146 corresponding to the height of reduced catalyst.

[0125] Section 141 of catalyst bed 140 may comprise catalyst particles of a single size and / or shape, although it will be understood that separate sections within catalyst bed 140 of catalyst particles of different sizes and / or shapes are contemplated within the scope of the present disclosure. The catalyst particles may have any suitable shape or configuration, e.g., spheres, pellets, cylinders, trilobes, tetralobes, pyramids, cones, stars, or others, and may have any suitable number and size of openings defined therethrough and / or notches or grooves defined on a portion of their surface. Separate sections corresponding to a single, different types of catalyst sizes and / or shapes may be provided within catalyst bed 140, for example, as axial or radial layers or pockets. In embodiments, catalyst particles of different sizes and shapes may be provided and mixed together within a catalyst body in any suitable configuration.

[0126] The catalyst particles in catalyst bed 140 may be a function of and cooperate with the support ceramic balls in sections 142, 144, and vice versa. In an embodiment, the catalyst particles are selected independently of the support ceramic balls.

[0127] Tube bundle 130 according to an embodiment is shown in FIGS. 6 and 7. Tube bundle 130 is configured to extend generally longitudinally about axis 1A-1A within shell 102 and is supported, from top to bottom, by top plate and tube support plate 150, multiple tube support plates 162, 163, 164, 165, catalyst support plate 154, and gas introduction plate 156. Distance 161 between top plate and tube support plate 150 and tube support plate 162, and between tube support plates 162, 163, 164, and 165, may be uniform along the length of tube bundle 130. In an embodiment, distance 161 may vary. Distance 167 between tube support plate 165 and catalyst support plate 154 may be greater than distance 161. Distance 169 between catalyst support plate 154 and gas introduction plate 156 may be less than distance 167. It will be understood that the depicted embodiment is exemplary only and that any arrangement of tube bundles 130 may be used.

[0128] The tubes 131 may define a uniform thickness and diameter along the longitudinal length of the tube bundle 130. In embodiments, the tubes 131 have a tapered thickness along the length of the tube bundle, with the thickness and / or diameter increasing near one or more plates 150, 162, 163, 164, 165, 154, 156 to support the plates. In embodiments, one or more tubes 131 of the tube bundle 130 may have an increased thickness relative to the other tubes 131 to increase structural support. For example, the tubes 131 extending closer to the center or outer edges of the tube bundle 130 may have an increased thickness relative to the other tubes 131, e.g., 10%, 20%, 25%, 33%, 50%, or any other suitable thickness. That is, the walls of such tubes 131 may have an increased thickness while maintaining the same inner diameter in embodiments. This advantageously allows multiple tubes 131 with increased thickness to carry reactants while supporting the tube bundle 130, thereby freeing up cross-sectional area for increased catalyst loading and more evenly distributed catalyst relative to other structural configurations.

[0129] In embodiments, the plurality of tubes 131 have a reduced thickness and / or an increased diameter near the bottom of the reactor 100, for example, to facilitate more efficient heat transfer at the bottom of the reactor 100 compared to the top of the reactor 100. Alternatively, one or more of the plurality of tubes 131 of the tube bundle 130 may include an internal tube rod configured to increase the rate at which reactants are preheated therein. The internal tube rod may extend part or all of the distance from the bottom of the plurality of tubes 131 to the top of the plurality of tubes 131.

[0130] In general, the tube bundle 130 and reactor 100 are advantageously modular in design and implementation. While existing shell-and-tube reactors are not easily scalable due to the significant rework that must be done to properly balance tube lengths and diameters, catalyst beds, shells, and other components, the design of reactor 100 advantageously allows for scaling based on multiple concentric band arrangements of tubes 131 on the tube bundle 130. The tube bundle 130 allows other geometric features of the reactor to remain unchanged even when multiple annular bands of tubes 131 are added (to increase the capacity of the reactor design for greater throughput or during debottlenecking efforts) or removed (to decrease the capacity of the reactor design). As a result, extensive redesign work can be avoided.

[0131] The tube bundle 130 can be configured such that one or more geometric constraints or ratios are maintained in any design, whether the reactor and tube bundle are configured for reduced or increased throughput in various designs. To ensure improved tube density, the average tube pitch (i.e., the center-to-center distance between the tubes) of the tube bundle is substantially constant throughout the tube bundle, and the annular bands and tubes defining it are spaced to maintain the constant tube pitch.

[0132] As another example, tube bundle 130 advantageously provides a desired ratio of the cumulative cross-sectional area of ​​the catalyst bed in a plan view of the reactor to the cumulative cross-sectional area of ​​the plurality of tubes 131 (i.e., the total radial surface area of ​​the plurality of tubes taken together) in the same plan view. In embodiments, the ratio of the cumulative cross-sectional area of ​​the catalyst to the cumulative cross-sectional area of ​​the plurality of tubes is in the range of 2 to 20, more specifically 5 to 12.

[0133] Whether annular bands of tubes 131 are added or removed from the design of the tube bundle 130, the cross-sectional area of ​​the tubes 131 relative to the catalyst bed can be simply and easily adjusted to remain within a suitable range so that the reactor's performance, and particularly its safety profile, is suitable. In embodiments, the addition or removal of one or more annular bands of tubes may not substantially change the cumulative cross-sectional area of ​​the catalyst relative to the cumulative cross-sectional area of ​​the tubes. In other embodiments, the tube bundle 130 can be designed such that the removal or addition of annular bands of tubes does not require a major redesign, but rather any other geometric or process-related parameters are targeted to allow engineers to simply and easily adjust the reactor to new required capacity or other requirements. Providing the tube bundle 130 with a specified relationship between the cross-sectional areas of the tubes and the catalyst bed improves heat distribution, which reduces hot spots and improves overall throughput through the reactor 100, thereby reducing the likelihood of runaway reactions.

[0134] The reactor 100 may be controlled and maintained during operation to control one or more characteristics of the catalyst bed 140 and / or the tube bundle 130. In some embodiments, the reactor 100 is configured to utilize temperature measurement devices to assess the distribution of heat across the cross-sectional area of ​​the catalyst bed. In particular, the reactor 100 may be controlled by assessing the radial temperature gradient within the reactor with depth (from the top end 105 to the bottom end 107) within the reactor 100 and / or the growth of said gradient with depth.

[0135] 12 and 13, catalyst support plate 154 is configured to support a total height of solid catalyst, such as the height of sections 142, 144 combined with the height of section 141. Catalyst support plate 154 also advantageously supports forces resulting from a pressure differential across catalyst bed 140. Catalyst support plate 154 may be positioned within shell 102 near catalyst removal nozzle 116 and / or handhole 118. Catalyst support plate 154 may define one or more openings 180, 181. Openings 180, 181 may comprise or define a plurality of openings, including a plurality of openings of a first size corresponding to opening 180 and a plurality of openings of a second size corresponding to opening 181, the plurality of openings extending through at least a portion of the thickness of catalyst support plate 154.

[0136] A first size of the opening 180 may correspond to a circumference of at least one tube 131 of the tube bundle 130. In embodiments, the first size of the opening 180 is greater than a circumference of the plurality of tubes 131 to allow for any degree of movement and / or thermal expansion of the plurality of tubes within the opening 180. The opening 180 may be defined through the catalyst support plate 154 depending on the arrangement of the plurality of tubes 131 within the tube bundle 130. A second size of the opening 181 is smaller than the first size of the opening 180, and the second size of the opening 181 may serve to allow for the flow of reactants, reaction products, and reaction by-products therethrough on their way to the exit nozzle 124.

[0137] In embodiments, one or more openings 180 may define the termination of a temperature measurement device. Opening 182 may be sized and configured to receive thermocouple insertion tube 126 and terminate an extension of thermocouple insertion tube 126 ( FIG. 7 ). Opening 182 may, in embodiments, extend only partially through the thickness of catalyst support plate 154. In embodiments, thermocouple insertion tube 126 may be welded to and plugged in catalyst support plate 154. Multiple tubes 131 may not be welded to catalyst support plate 154 to account for thermal expansion effects.

[0138] The size of plurality of openings 181 and / or the average distance between plurality of openings 181 may be a function of the thickness of catalyst support plate 154, such that the size of plurality of openings 181 is proportional to the thickness of catalyst support plate 154 and / or the distance between plurality of openings 181 is inversely proportional to the thickness of catalyst support plate 154. That is, the thicker the catalyst support plate 154, the larger the diameter of plurality of openings 181 and / or the smaller the distance between plurality of openings 181. In embodiments, catalyst support plate 154 may have a thickness of 20 to 500 mm, more specifically 50 to 300 mm, and in embodiments, 110 mm, while plurality of openings 181 may have a diameter of 1 to 50 mm, more specifically 5 to 25 mm, and in embodiments, 10 mm.

[0139] As seen in the enlarged view of FIG. 13 , the plurality of openings 180 may extend in a pattern or arrangement corresponding to the arrangement of the plurality of tubes 131 within the tube bundle 130, as described in further detail herein. The plurality of openings 181 may extend between each of the plurality of openings 180. The plurality of openings 181 may define any suitable pattern or arrangement, such as an extension direction 183A defining a straight line and / or a transverse extension direction 183B. Other patterns or arrangements of the plurality of openings 181 are contemplated within the scope of the present disclosure. The plurality of openings 181 may be spaced apart from one another by any distance, for example, in embodiments, along one or both of the directions 183A, 183B, by a distance of 1 to 30 mm between the centers of adjacent plurality of openings 181, more specifically, by a distance of 5 to 20 mm between the centers of adjacent plurality of openings 181, and in embodiments, by a distance of 15 mm between the centers of adjacent plurality of openings 181. The distance between the centers of adjacent plurality of openings 181 need not be uniform across the entire surface of the catalyst support plate 154, but rather may vary as appropriate.

[0140] Catalyst support plate 154 may define, at its periphery, a band 184 of material forming catalyst support plate 154 that does not define any of openings 180, 181. Band 184 extends partially or completely around the periphery of catalyst support plate 154 and advantageously facilitates welding or other suitable attachment of catalyst support plate 154 to the inner surface of shell 102. In an embodiment, band 184 may extend into a recess defined by the inner surface of shell 102 and then be welded to the recess. Band 184 may extend any suitable distance in the radial direction, for example, 5 mm.

[0141] 11 , gas inlet plate 156 may be disposed below catalyst support plate 154 and may include a plurality of apertures 155 defined through at least a portion of the thickness of gas inlet plate 156. The plurality of apertures 155 may be circular apertures defined through gas inlet plate 156 in accordance with the arrangement of tubes 131 in tube bundle 130 and aligned with the arrangement of apertures 180 in catalyst support plate 154. In embodiments, gas inlet plate 156 is substantially solid, lacking apertures other than apertures 155, forcing incoming reactants into tubes 131. Tubes 131 may be seal welded and / or strength welded to gas inlet plate 156. It will be understood that when one component is described herein as being welded to another component, seal welding, strength welding, a combination thereof, or any other type of attachment is contemplated.

[0142] 8-9, reactor 100 may further include at least one tube support plate 150, 162, 163, 164, 165, which may be longitudinally spaced apart along the axial, or longitudinal, length of tube bundle 130. While tube support plates 150, 162, 163, 164, 165 are shown and depicted, it will be understood that more or fewer support plates may be provided. Upper feed tube support plate 150 may be substantially the same as tube support plates 162, 163, 164, 165, and may include or omit one or more features. For example, upper feed tube support plate 150 may have the same features as tube support plates 162, 163, 164, 165, and may further include one or more spacers configured to cooperate with the upper plate, as described in more detail below.

[0143] Tube support plates 150, 162, 163, 164, 165 may include at least one annular band 168 configured to maintain the position of at least one tube 131. At least one annular band 168 includes at least one bracket 172 configured to extend around a portion of a tube 131 of tube bundle 130. In embodiments, at least one bracket 172 extends around the entire tube 131. The bracket 172 may be configured to removably attach to tube 131.

[0144] In embodiments, brackets 172 may extend around only a portion of, or less than, the entire tube. Brackets 172 may advantageously cooperate with beams 173 extending between the brackets 172 and adjacent brackets 172 attached to adjacent tubes 131. Brackets 172 may be removably or non-removably connected to beams 173, for example, to define a fillet connection. Annular band 168 may be defined by a series of connected brackets 172 and beams 173 that define a generally annular arrangement with the corresponding tubes 131.

[0145] Annular band 168 is concentrically disposed with adjacent annular bands 168 of tube support plates 150, 162, 163, 164, 165, and annular band 168 may optionally be centered about longitudinal axis 1A-1A of the reactor. Brackets 172, beams 173, radial struts 166, and annular band 168 cooperate to define a tube support plate. While annular band 168 is shown and represented, it will be understood that any suitable configuration may be used, including asymmetric, offset, or non-annular arrangements. While the cooperation of various components is described as defining a tube support plate, it will be understood that the tube support plate may have any suitable configuration and is not intended to be limited thereby.

[0146] At least one tube support plate 150, 162, 163, 164, 165 defines at least one radial strut 166 connected to at least one annular band 168 at attachment points 169 and / or to outer support band 170 at attachment points 171. The tube support plate may define a plurality of radial struts 166 arranged radially symmetrically, for example, at 22.5° increments, 30° increments, 45° increments, 90° increments, 120° increments, 180° increments, other increments evenly divisible by 360°, or in other manners. In other embodiments, the plurality of radial struts 166 are arranged asymmetrically in any suitable manner.

[0147] The outer support bands 170 may define a substantially continuous band of support material, such as stainless steel, that provides sufficient rigidity, strength, and / or support for the tube support plates and / or facilitates attachment of the outer support bands 170 to the interior surface of the reactor shell 102. While eight radial struts 166 are shown and depicted with respect to the embodiment of Figures 9 and 10, it will be understood that more or fewer radial struts 166 may be provided and that the tube support plates 150, 162, 163, 164, 165 may not all have the same number or arrangement of radial struts or other components.

[0148] The plurality of radial struts 166 may extend straight outward from the center of the tube support plate to the outer support band 170, or may define a curved, bent, serpentine, or other configuration. The plurality of radial struts 166 may be formed of any suitable material, such as stainless steel, and may define heat-resistant properties to maintain desired rigidity and strength under reactor conditions. The plurality of radial struts 166 advantageously define attachment points 169 between the annular band 168 and the plurality of radial struts 166. The attachment points 169 may be removable or non-removable and may define any suitable connection, such as being welded together or attached by suitable fasteners. The tube support plate may be configured to move with the plurality of tubes 131 due to thermal expansion and contraction and may be formed of a high-temperature resistant material, such as steel (e.g., stainless steel), ceramic, polymeric material, composite material, or others.

[0149] In embodiments, tube support plates 150, 162, 163, 164, 165 may be manufactured using any suitable means. In embodiments, tube support plates 150, 162, 163, 164, 165 are formed from a single, solid plate from which material is removed, for example, by water jet cutting. In other embodiments, the radial struts and annular bands are manufactured separately and assembled to form the tube support plate.

[0150] Upper feed tube support plate 150 may further define one or more spacers 174 on its upper surface. Spacers 174 may be attached to one or more structures of upper feed tube support plate 150 in any suitable manner, such as by welding. Spacer 174 may extend a predetermined height and may define an opening within its center. The opening may include one or more threads configured to mate with one or more threads of a fastener, as described in more detail below with respect to top plate 190. Spacers 174 may extend around upper feed tube support plate 150 in any suitable arrangement and in any suitable number.

[0151] For example, the spacers 174 may define three concentric ring patterns 175 ( FIG. 9 ) around the upper feed tube support plate 150 when the spacers 174 are attached to the plurality of radial struts 166. In an embodiment, the spacers 174 extend along four radial struts 166 between the first and second annular bands, between the seventh and eighth annular bands, and between the thirteenth and fourteenth annular bands. A total of four spacers 174 may be positioned on each concentric ring pattern 175 such that a corner portion of each segment of the upper plate 190 is secured thereto, as described below.

[0152] The arrangement of the plurality of radial struts 166 advantageously provides secure attachment of the plurality of tubes 131 of the tube bundle 130 while minimizing interference with catalyst distribution as the catalyst is loaded from the top 105 of the reactor 100. For example, the plurality of radial struts 166 are configured to minimize uneven distribution of catalyst as the catalyst particles flow into the shell 102. In an embodiment, the plurality of radial struts 166 of adjacent tube support plates 162, 163, 164, 165 may be axially aligned along the longitudinal extension of the reactor 100.

[0153] In other embodiments, as seen in FIG. 10B , the radial struts 167 of adjacent tube support plates may be offset from the radial struts 166 to promote even distribution of catalyst during loading. The degree of offset may be any suitable degree. In embodiments, the radial struts 167 are offset by a distance corresponding to half the angular distance between the radial struts 166. In the embodiment of FIG. 10B , the radial struts 166 are offset from one another by 45°, and the offset between the radial struts 167 is 22.5°. Subsequent tube support plates may be staggered. The radial struts 166 of adjacent tube support plates may be offset down the longitudinal length of the reactor to define a spiral or helix pattern. The depicted embodiment is exemplary, and any other arrangement may be used as appropriate.

[0154] The tube bundle 130 may be arranged such that the innermost annular band 168A of at least one tube support plate includes six brackets, each configured to correspond to the six innermost rings of tubes of a first size. The first size may be, for example, 0.5 to 3 mm in diameter, more specifically 1 to 2 mm in diameter, and in embodiments, 1.5 mm in diameter. The second annular band 168B of at least one tube support plate includes ten brackets, each configured to correspond to the ten rings of tubes of the tube bundle of the first size. The third annular band 168C of at least one tube support plate includes fourteen brackets, each configured to correspond to the fourteen rings of tubes of the tube bundle of the second size. The second size may be, for example, 0.5 to 5 mm in diameter, more specifically 1 to 4 mm in diameter, and in embodiments, 2.5 mm in diameter.

[0155] The fourth annular band 168D of the at least one tube support plate includes 18 brackets each configured to correspond to a ring of 18 tubes of the first size tube bundle, the fifth annular band 168E of the at least one tube support plate includes 22 brackets each configured to correspond to a ring of 22 tubes of the first size tube bundle, and the sixth annular band 168F of the at least one tube support plate includes 26 brackets each configured to correspond to a ring of 26 tubes of the first size tube bundle.

[0156] The seventh annular band 168G of the at least one tube support plate includes 30 brackets, each configured to correspond to 30 rings of tubes in the second size tube bundle. The eighth annular band 168H of the at least one tube support plate includes 34 brackets, each configured to correspond to 34 rings of tubes in the first size tube bundle. The ninth annular band 168I of the at least one tube support plate includes 36 brackets, each configured to correspond to 36 rings of tubes in the first size tube bundle. The tenth annular band 168J of the at least one tube support plate includes 42 brackets, each configured to correspond to 42 rings of tubes in the first size tube bundle.

[0157] The eleventh annular band 168K of the at least one tube support plate includes 46 brackets, each configured to correspond to a ring of 46 tubes of the second size tube bundle. The twelfth annular band 168L of the at least one tube support plate includes 50 brackets, each configured to correspond to a ring of 50 tubes of the first size tube bundle. The thirteenth annular band 168M of the at least one tube support plate includes 54 brackets, each configured to correspond to a ring of 54 tubes of the first size tube bundle. The fourteenth annular band 168N of the at least one tube support plate includes 58 brackets, each configured to correspond to a ring of 58 tubes of the second size tube bundle.

[0158] While first through fourteen annular zones are shown and represented, it will be understood that reactor embodiments of the present disclosure facilitate the construction of modular reactors that better accommodate different facility throughput requirements than existing reactor designs. For example, engineers can modify the depicted tube bundle 130 to have more, fewer, and / or different annular zones, as needed. To expand the tube bundle 130 and reactor 100 as a whole to accommodate higher annual plant production capacity, such as during debottlenecking efforts, additional annular zones can be added to increase the number of tubes and expand the tube bundle outward in a simple retrofit. For example, the attachments 171 between the radial struts 166 and the outer zones 170 can be removed so that additional annular zones can be added to the tube support plate, and the outer zones 170 can be replaced around the new annular zones. To this end, the outer zones 170 can be configured with an expandable circumference.

[0159] Conversely, to downsize reactor 100, annular bands, such as the outermost annular bands, may be removed to reduce the size of the tube bundle to fit a smaller reactor shell and / or result in a corresponding lower annual plant capacity. This may be done, for example, by removing the attachments 169 between the annular bands and the radial struts.

[0160] Furthermore, the arrangement of the annular bands as shown allows for the addition or removal of annular bands and associated brackets and tubes while accommodating the configuration of the radial struts. As can be seen, the number of brackets and tubes increases so that the tubes are arranged in a substantially uniform distribution and with sufficient spacing between the tubes to allow catalyst and reactants to pass therebetween and for annular bands to be added or removed generally without compromising the design of the radial struts and tube supports.

[0161] In an embodiment, the ninth annular band 168I (or any other) of the at least one tube support plate further comprises a bracket 172 corresponding to at least one thermocouple insertion tube 126, wherein the at least one thermocouple insertion tube 126 is of the first tube size. Providing the thermocouple insertion tube 126 with a bracket 172 allows a temperature measurement device to be inserted into the tube bundle, preferably into any region of the tube bundle surrounded by the catalyst and multiple tubes, to obtain accurate temperature measurements along the longitudinal length of the reactor.

[0162] The upper and feed tube support plates, like tube support plates 162, 163, 164, 165, may include one or more radial struts 166, an outer band 170, and one or more brackets 172 configured to engage and / or surround tubes 131 of tube bundle 130. The radial struts 166 of upper feed tube support plate 150 may be similarly or correspondingly positioned to the struts 166 of feed tube support plates 162, 163, 164, 165 and may be axially separated by a suitable angle 176 ( FIG. 9 ), e.g., 45°. It will be understood that other angles or arrangements are contemplated by this disclosure.

[0163] Brackets 172 of upper feed tube support plate 150 define or extend near the terminus of tubes 131 where preheated reactants exit tubes 131 and then flow downward in second direction F2. Thermocouple insertion tube 126 may extend any distance above the distance or extent of the top of tube 131, which may facilitate easier insertion of temperature measurement devices from thermocouple port 106 into thermocouple insertion tube 126. Like tube support plates 162, 163, 164, 165, upper feed tube support plate 150 may be configured to increase or decrease in size to suit the desired capacity of reactor 100.

[0164] The arrangement of the tube bundle 130 and tube support plates 150, 162, 163, 164, 165 can advantageously account for reactor heat transfer and reactor dynamics.

[0165] 14-16, top plate 190 is shown. Top plate 190 may be mounted on or above upper feed tube support plate 150. Top plate 190 may be modular in configuration and may define four separate segments 192 surrounded by flanges 191. Top plate 190 may define plate edges 194, one or more tube holes 202 defined through at least a portion of the thickness of plate 190, and one or more gas openings 204 defined through at least a portion of the thickness of plate 190. The tube holes 202 may be configured to generally align with the placement of tubes 131 of tube bundle 130 and to facilitate the passage of preheated reactants from the tubes 131 into volume 113 (FIG. 5B) of reactor 100.

[0166] The gas openings 204 facilitate the passage of preheated reactants into the catalyst bed 140 and ensure proper flow distribution. The top plate 190 may be configured to create a small pressure drop to make the flow entering the catalyst bed as uniform as possible. The top plate 190 is advantageously configured to achieve improved uniformity of flow distribution using a simplified design as illustrated and depicted, as opposed to existing approaches that may utilize heavy and / or complex designs that are difficult and / or costly to manufacture and / or manipulate for maintenance purposes.

[0167] Because top plate 190 may extend outward to flange 191, gas openings 204 may extend substantially to edge 194 without leaving gaps as in catalyst support plate 154. Top plate 190 may have a reduced thickness compared to catalyst support plate 154. In embodiments, top plate 190 has a thickness of 1 to 25 mm, more specifically 5 to 15 mm, and in embodiments 8 mm.

[0168] Top plate 190 is configured to be removably attached to shell 102 and / or top plate and tube support plate 150 by any suitable mechanism, for example, by use of fasteners 196 that cooperate with corresponding openings 193 ( FIG. 15 ) at the edge of each section of plate 190. Fasteners 196 of top plate 190 may cooperate with one or more spacers 174 that extend between top plate 190 and upper feed tube support plate 150 and may be welded, e.g., tack welded, to upper feed tube support plate 150.

[0169] In embodiments, the spacers 174 may have a height and / or circumference sufficient to receive mating ends of the fasteners 196 within tracks or recesses defined through a portion of the thickness of the spacers 174, which may enable a secure attachment of the top plate 190 to the upper feed tube support plate 150. The height of the spacers 174 may be 1 to 30 mm, more specifically 5 to 20 mm, and in embodiments 15 mm. The spacers 174 may be welded to the radial struts 166, the annular band 168, the brackets 172, or other objects. As can be seen, the fasteners 196 and corresponding spacers 174 may be positioned such that the fasteners and spacers 196, 174 are provided at each corner and along the interior edges of the sections 194 of the top plate 190.

[0170] Top plate 190 may further include or cooperate with one or more load rings 195. The load rings 195 may be any suitable component configured to facilitate positioning and / or removal of sections 194 of top plate 190. Load rings 195 may be attached through one or more gas openings 204 or at any other suitable location, and may be removably secured to top plate 190 and define components for manipulating top plate 190. In an embodiment, load ring 195 is configured to allow an operator to grasp top plate 190 with a tool to lift top plate 190 away from reactor shell 102.

[0171] By modularly providing top plate 190 with separate sections 194, top plate 190 can be more easily removed and replaced during maintenance procedures without sacrificing its ability to distribute reactants and secure catalyst bed 140. The modular configuration of top plate 190 makes the manufacturing process less costly and complex, as multiple identical sections 192 can be manufactured rather than a single, monolithic plate 190. One advantage of the top plate 190 arrangement is that a plant worker can stand on one of the sections 194 of top plate 190 while loading catalyst through an opening provided by a removed section 194.

[0172] 17-19, a retainer plate 210 for use with one or more nozzles of the reactor 100 is shown and depicted. The retainer plate 210 may secure the catalyst removal nozzle 116 and / or the hand hole 118. The retainer plate 210 may include a handle 212 and is configured to cooperate with a lip 214 defined by the nozzle 116. In embodiments, the nozzle 116 defines multiple lips 214 arranged circumferentially around the nozzle opening in any suitable pattern, and the retainer plate 210 is configured to abut the inner surface of the lip 214 as seen in FIG. 17. In embodiments, the multiple lips 214 are spaced apart by any angle, e.g., 15°, 20°, 30°, 45°, 60°, 90°, or others. The arrangement of the multiple lips 214 may be symmetrical or asymmetrical. The flange 117 of the nozzle 116 may define one or more openings 211 through which suitable fasteners may be received to connect the nozzle 116 to a suitable spool.

[0173] In certain embodiments, the plurality of lips 214 do not extend around the bottommost section B of the circumferential opening defined by the catalyst removal nozzle 116 or hand hole 118. Rather, as seen in Figure 19, the bottommost section B is unobstructed to allow the catalyst particles to flow freely under the influence of gravity during catalyst removal. The placement of the retention plate 210 prevents the catalyst from flowing too quickly during catalyst removal.

[0174] Turning to FIG. 20 , a reactor 300 according to an embodiment is shown and represented. Reference numerals in the “300” series may include similar or identical features to those already represented by reference numerals in the “100” series. The reactor 300 includes a shell 302 in which a tube bundle having a top plate 350, as described above, may be received and secured, and which defines an inlet nozzle 320 and an outlet nozzle 324. The shell 302 may further include or cooperate with a domed top 304 that defines and / or supports a thermocouple insertion nozzle 306. The domed top 304 may be secured to the shell 302 by a flange 312. The reactor 300 extends longitudinally about an axis 20A-20A. A catalyst bed 340 may extend a suitable height within the interior space defined by the reactor shell 302.

[0175] Reactor 300 further defines a thermocouple insertion tube 326 extending about, or substantially parallel to, or aligned with longitudinal axis 20A-20A and through catalyst bed 340. Thermocouple insertion tube 326 may be integral with or separate from a tube bundle as described above. Thermocouple insertion tube 326 is configured to receive temperature measurement device 310, which also extends about longitudinal axis 20A-20A. Temperature measurement device 310 may be a multi-element thermocouple. The multi-element thermocouple is configured to obtain temperature measurements at multiple locations along reactor 300.

[0176] 20 , the temperature measurement device 310 may include eight measurement locations 382A, 382B, 382C, 382D, 382E, 382F, 382G, and 382H along the length of the reactor 300 and extending to the terminal end 327. The temperature measurement device 310 may have an overall length 330I. The locations 382A, 382B, 382C, 382D, 382E, 382F, 382G, and 382H may be spaced apart by distances 330A, 330B, 330C, 330D, 330E, 330F, and 330G, respectively. Distances 330A, 330B, 330C, 330D, 330E, 330F, 330G may be the same distance such that the measurement locations are evenly spaced along reactor 300, or may be different distances depending on the needs of a particular process.

[0177] Thermocouple insertion tube 326 may be suitably configured to enable temperature measurement device 310 to obtain measurements at locations 382A, 382B, 382C, 382D, 382E, 382F, 382G, and 382H, for example, by defining openings in thermocouple insertion tube 326 at or near locations 382A, 382B, 382C, 382D, 382E, 382F, 382G, and 382H to enable temperature measurement device 310 to measure the temperature inside the reactor. While a temperature measurement device has been depicted, it will be understood that the disclosure extends to other types of sensors and is not limited to multi-element thermocouples. In embodiments, different sensors may be placed at different locations as desired.

[0178] The temperature measurement device 310, reactor 300, and thermocouple insertion tube 326 advantageously facilitate improved process control by reducing the number of thermocouple junctions and providing high-granularity reactor condition data at multiple locations within the reactor while simultaneously minimizing the risk of leaks, particularly for high-pressure and / or high-temperature service and / or reactions involving hydrogen- or oxygen-sensitive catalysts. The configuration of the temperature measurement device 310, reactor 300, and thermocouple insertion tube 326 further improves the scalability of reactor design, as the placement of the thermocouple insertion tube 326 and temperature measurement device 310 allows for accurate measurement of internal reactor conditions regardless of reactor size, mitigating the difficulty of monitoring reactors with thermowells located radially from the reactor sidewall and, for larger reactors, disproportionately measuring conditions near the shell rather than near the center of the reactor.

[0179] Additionally, as seen in at least FIGS. 2 and 7, the reactor may include multiple temperature measurement devices. The temperature measurement devices may be positioned in any suitable configuration relative to the reactor shell and relative to each other. In the embodiments of FIGS. 2 and 7, for example, the temperature measurement devices may be offset from the central longitudinal axis of the reactor by the same distance and positioned opposite each other. The distance between the multiple temperature measurement devices may be configured to minimize interference with or disturbance to the heat distribution within the reactor, particularly the catalyst bed. The distance may be selected to be above a minimum threshold at which hot spots occur between or near the multiple temperature measurement devices due to resulting disruptions to reactant and product flow, and thus heat distribution. Positioning the multiple temperature measurement devices above the minimum threshold thereby avoids disturbances to reactor performance and improves the accuracy of measurements.

[0180] The multiple temperature measurement devices may serve different purposes and / or may be complementary to one another. In the embodiment of Figures 2 and 7, the temperature measurement devices are multiple multi-element thermocouples as depicted with respect to Figure 20. One of the multiple multi-element thermocouples may be connected to a process control system, while a second of the multiple multi-element thermocouples may be connected to a safety instrumented system.

[0181] Providing multiple multi-element thermocouples advantageously confirms the measurement of temperature at specific locations, i.e., heights, within the reactor. Differences, if any, between the signals obtained from multiple multi-element thermocouples can be used to determine, for example, the occurrence of hot spots at specific heights, allowing an operator to make adjustments as needed. It will be appreciated that any suitable number of thermocouples in any suitable configuration can be used.

[0182] An embodiment of the reactor includes a plurality of feed tubes extending longitudinally through the reactor and catalyst bed. The tube bundle may define a plurality of thermocouple insertion tubes extending parallel to the plurality of feed tubes and configured to receive a temperature measurement device, such as a multi-element thermocouple, therethrough. The plurality of thermocouple insertion tubes may be configured to extend at different distances from the center of the reactor.

[0183] The multiple distances may be configured to allow measurement of temperature distribution at multiple different distances from the center. In particular, this may be useful for validating reactor designs at a specific scale and further enhance the scalability of reactors of embodiments of the present disclosure. This further enhances process control of the reactor, with increased granularity in temperature measurements and associated responses that can be adjusted using a process control system. In embodiments, the radial configuration of the multiple thermocouple insertion tubes may be determined to coincide with predicted hot spots.

[0184] This allows operators to quickly and accurately determine when a hot spot has formed and respond accordingly, thereby preventing a runaway reaction. The configuration of the multiple thermocouple insertion tubes can also be determined for the tube bundle to correspond to the size of the reactor shell. In smaller reactors, for example, fewer thermocouple insertion tubes can be utilized, while the number of thermocouple insertion tubes, and the complexity of their configuration, can increase in larger reactors.

[0185] Providing a reactor according to the disclosed embodiments addresses the problems of existing reactors being difficult to access when maintenance is required and difficult to scale the reactor based on the capacity needs of the facility. Reactor embodiments of the present disclosure advantageously provide a reactor that is modularly arranged based on the capacity needs of the facility design, is easily accessible for maintenance and catalyst loading, facilitates improved and even distribution of catalyst, reactants, and heat, and / or has a robust yet flexible reactor interior configured to provide robust structural support during construction, transportation, installation, and operation.

[0186] While the reactor has been shown and described in the drawings and foregoing description, it is understood that they are intended to be illustrative and not restrictive in character, having shown and represented preferred embodiments only, and that the following claims desire to cover all changes, equivalents, and modifications that fall within the spirit of the defined embodiments.

[0187] Thus, features of the disclosed embodiments may be combined or arranged to achieve certain advantages, as will be understood by those skilled in the art from this disclosure. Likewise, features of the disclosed embodiments may provide independent benefits applicable to other embodiments not detailed herein. In particular, any feature from one disclosed embodiment may be employed in another disclosed embodiment.

[0188] It is to be understood that not all objects or advantages may be achieved in accordance with any embodiment of the present disclosure, and one skilled in the art will recognize that the reactor may be implemented or performed in a manner that achieves or optimizes one advantage or advantages as taught without achieving other objects or advantages as taught or suggested.

[0189] Those skilled in the art will recognize the interchangeability of the various features disclosed. In addition to the variations described, other known equivalents for each feature may be mixed and matched by those skilled in the art to manufacture or use a reactor under the principles of the present disclosure. Those skilled in the art will understand that the described features may be adapted to other types of reactors, reaction suites, chemical species, and processes. Thus, the present disclosure, and its embodiments and variations, may be utilized in any chemical process, including but not limited to methanol synthesis processes or shell-and-tube reactors.

[0190] While the present disclosure describes certain exemplary embodiments and examples of reactors, it will therefore be appreciated by those skilled in the art that the present disclosure extends beyond the specifically disclosed embodiments to other alternative embodiments and / or uses of the present disclosure, as well as obvious modifications and equivalents thereof, and it is not intended that the present disclosure be limited by the particular disclosed embodiments.

[0191] Furthermore, unless otherwise indicated, numerical values ​​expressing quantities, components, distances, or other measurements used in the specification and claims are understood to be optionally modified by the term "about" or its equivalents. When the terms "about," "approximately," "substantially," and the like are used in conjunction with a stated quantity, value, or condition, they may be understood to mean an amount, value, or condition that deviates by less than 20%, less than 10%, less than 5%, less than 1%, less than 0.1%, or less than 0.01% of the stated quantity, value, or condition. As used herein, the term "between" includes any referenced endpoints. For example, "between 2 and 10" includes both 2 and 10.

Claims

1. A reactor comprising: a shell defining an interior space configured to receive a catalyst; at least one inlet nozzle; a tube bundle comprising a plurality of tubes centered about the longitudinal axis of the reactor; Equipped with The reactor comprises at least one annular band, the at least one annular band comprising at least one bracket configured to extend around a portion of the tubes of the tube bundle.

2. at least one catalyst support plate; Gas inlet plate, or Top Plate 10. The reactor of claim 1 further comprising:

3. 10. The reactor of claim 1, wherein the catalyst is a solid catalyst.

4. 10. The reactor of claim 1, wherein the reactor further comprises at least one tube support plate.

5. 4. The reactor of claim 3, wherein the reactor further comprises a catalyst support plate, the solid catalyst being disposed adjacent to the catalyst support plate.

6. 10. The reactor of claim 1, wherein the shell is configured to receive at least one solid catalyst, the solid catalyst comprising a shape defining at least one of a pellet, a ring, a tablet, and a sphere.

7. 10. The reactor of claim 1, wherein the reactor further comprises a catalyst support plate, the catalyst support plate configured to support the catalyst at a predetermined height.

8. 10. The reactor of claim 1, wherein the reactor further comprises a catalyst support plate, the catalyst support plate defining one or more openings.

9. 10. The reactor of claim 8, wherein the one or more openings comprise a plurality of openings of a first size and a plurality of openings of a second size, the plurality of openings extending through at least a portion of a thickness of the catalyst support plate.

10. 10. The reactor of claim 9, wherein the first size corresponds to a circumference of at least one tube of the tube bundle and the second size is smaller than the first size.

11. 11. The reactor of claim 10, wherein the plurality of openings of the first size are defined through the catalyst support plate according to an arrangement of the plurality of tubes in the tube bundle.

12. 10. The reactor of claim 1, wherein the reactor further comprises a gas inlet plate having a plurality of openings defined through a thickness of the gas inlet plate, the plurality of openings being a plurality of circular openings defined through the gas inlet plate according to the arrangement of the plurality of tubes of the tube bundle.

13. 13. The reactor of claim 12, wherein the gas introduction plate comprises a second plurality of openings defined through a thickness of the gas introduction plate, the second plurality of openings having a different size and / or shape than the plurality of circular openings.

14. 5. The reactor of claim 4 wherein said at least one tube support plate defines a plurality of concentric annular bands.

15. 15. The reactor of claim 14, wherein said at least one tube support plate defines at least one radial strut connected to at least one of said plurality of annular bands.

16. 15. The reactor of claim 14, wherein an innermost annular band of said at least one tube support plate comprises a predetermined number of brackets each configured to correspond to a concentric zonal ring of the same predetermined number of innermost tubes of said tube bundle, and a second annular band of said at least one tube support plate comprises an equal or greater number of brackets compared to said innermost annular band, the brackets of said second annular band each configured to correspond to a corresponding number of tubes in a second concentric zonal ring of said tube bundle.

17. 17. The reactor of claim 16, wherein one of the plurality of annular bands of the at least one tube support plate comprises a bracket corresponding to at least one thermocouple insertion tube, the at least one thermocouple insertion tube configured to receive a temperature measurement device, the temperature measurement device configured to obtain temperatures at a plurality of longitudinal locations within the reactor.

18. 1. A methanol synthesis reactor comprising: a shell defining an interior space configured to receive a solid catalyst; a tube bundle comprising a plurality of tubes, the plurality of tubes being centered about a longitudinal axis of the reactor; at least one inlet nozzle; an outlet nozzle, said outlet nozzle located near a bottom of said shell; a catalyst support plate, the outlet nozzle being disposed below the catalyst support plate; a plurality of tube support plates for supporting the tubes of the tube bundle; Gas introduction plate and Equipped with a methanol synthesis reactor, wherein the gas introduction plate is disposed near the inlet nozzle, and the inlet nozzle is disposed below the gas introduction plate;

19. 20. The reactor of claim 18, wherein the tube bundle is configured to facilitate a greater degree of heat transfer near the bottom of the reactor relative to the top of the reactor.

20. A reactor comprising: a shell defining an interior space configured to receive a catalyst; at least one inlet nozzle; a tube bundle comprising a plurality of tubes centered about the longitudinal axis of the reactor; Equipped with The reactor further comprises a gas inlet plate; the gas inlet plate includes a plurality of first openings defined through a thickness of the gas inlet plate, the plurality of first openings being defined through the gas inlet plate according to an arrangement of the plurality of tubes in the tube bundle; the gas introduction plate includes a plurality of second openings defined through a thickness of the gas introduction plate, the plurality of second openings having a different size and / or shape than the plurality of first openings, the plurality of second openings being within the interior space defined by the shell, and the plurality of second openings functioning to permit flow of at least one of reactants, reaction products, or reaction by-products through a pathway to an exit nozzle.

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