Reactor and process for endothermic reactions at high temperatures

Abstract

An endothermic catalytic reactor apparatus comprises a radiant furnace including a burner configured to provide thermal energy to the furnace, an inlet section and an outlet section, and a reactor located within the furnace and configured to receive radiant thermal energy. The reactor comprises one or more static helical spirals that define a flow path within the reactor moving from the inlet section to the outlet section. The helical spirals may hold a catalyst on their outer surface to provide an unobstructed defined path. Inlet port(s) are located on the inlet section and are configured to receive a reactive starter material. An outlet port is located near the outlet section and is configured to discharge the product from the reactor. The reactor is configured to allow the starter material to receive radiant thermal energy and interact sufficiently with the catalyst, thereby causing a reaction to occur that converts the starter material into a product.

Description

Technology Field

[0001] Cross-reference regarding related applications

[0002] This application claims the benefit of U.S. Patent Application No. 17 / 887,792 filed August 15, 2022 and U.S. Provisional Application No. 63 / 315,808 filed March 2, 2022, all of which are incorporated herein by reference as is.

[0003] Technology field

[0004] The present disclosure relates to an endothermic catalytic reactor apparatus comprising a furnace and a reactor. Background Technology

[0005] An endothermic process is any process that involves an increase in the enthalpy or internal energy of a system. In such processes, a closed system typically absorbs thermal energy from its surroundings, which can be heat transfer into the system. For example, if more energy is required to break a bond than is being released, energy is absorbed and an endothermic reaction occurs.

[0006] The present disclosure provides an endothermic catalytic reactor apparatus comprising a radiative furnace and an endothermic reactor. The radiative furnace includes a burner configured to provide thermal energy to the furnace. The reactor has an inlet section and an outlet section, is located within the furnace, and is configured to receive radiative thermal energy from the furnace. The reactor includes one or more static helical spirals defining a flow path within the reactor, allowing a material to follow the defined flow path to move from the inlet section to the outlet section. The helical spirals may be configured to hold a catalyst on their outer surface. One or more inlet ports are located at the inlet section and are configured to receive a reactive starting material. An outlet port is located on or near the outlet section and is configured to discharge a product from the reactor. The reactor is configured to allow the starting material to receive radiative thermal energy and interact sufficiently with the catalyst, thereby causing a reaction to occur that converts the starting material into a product. Brief explanation of the drawing

[0007] FIG. 1 is a schematic front elevation view of a reactor apparatus according to the present disclosure. FIG. 2 is a schematic front elevation view of a reactor device according to the present disclosure. Specific details for implementing the invention

[0008] It should be understood that the present disclosure may assume various alternative variations and step sequences, except as expressly described otherwise. As a non-limiting example, FIGS. 1 and 2 illustrate the axis of the reactor (105) and the reaction flow proceeding downward in a vertical position, but this is not mandatory. The axis of the reactor (105) may be vertical, horizontal, or any orientation suitable for implementation. Accordingly, unless otherwise indicated, the numerical parameters described in the following description and the appended claims are approximations that may vary depending on the desired characteristics to be obtained. At least, each numerical parameter should be interpreted in terms of at least the number of reported significant digits and by applying general approximation techniques, not as an attempt to limit the application of the principle of equivalence to the scope of the claims.

[0009] Although the numerical ranges and parameters describing the broad scope of this disclosure are approximations, the numerical values ​​described in specific examples are reported as accurately as possible. However, any numerical value inherently contains a specific error that necessarily arises from the standard deviation found in each of their test measurements.

[0010] Additionally, it should be understood that any numerical range cited herein is intended to include all sub-ranges contained therein. For example, the range “1 to 10” is intended to include all sub-ranges between (and including) the mentioned minimum value of 1 and the mentioned maximum value of 10, that is, having a minimum value of 1 or greater and a maximum value of 10 or less.

[0011] All ranges are comprehensive and combinable. For example, the term “range of 0.06 to 0.25 wt%, or range of 0.06 to 0.08 wt%” will include 0.06 to 0.25 wt%, 0.06 to 0.08 wt%, and 0.08 to 0.25 wt%, respectively. Additionally, when a range is given, any endpoint of these ranges and / or numbers mentioned within these ranges may be combined within the scope of the present disclosure.

[0012] As used herein, unless otherwise explicitly specified, all numbers, such as those expressing values, ranges, amounts, or percentages, may be interpreted as if preceded by the word “about,” even if the term does not explicitly indicate otherwise. Unless otherwise specified, the plural includes the singular, and vice versa. As used herein, the term “comprising” and similar terms mean “comprising but not limited thereto.”

[0013] As used herein, the linking term "comprising" (and other corresponding terms such as "containing" and "comprising") is "open" and open to the inclusion of unexplained content. Although described by the term "comprising," the terms "essentially comprising" and "comprising" are also included within the scope of this disclosure.

[0014] As used in this specification, singular expressions include plural references unless explicitly and clearly limited to a single reference.

[0015] As used herein, the term “defined path” refers to a spiral path(s) through a reactor defined on the surface of a spiral spiral(s) and a distance from the inner side of the reactor wall to the outer surface of an optional central shaft extending along the central axis of the reactor.

[0016] As used herein, the term “endothermic reactor” refers to a reactor configured to allow a chemical reaction to occur that absorbs thermal energy or heat from its environment. The absorbed energy provides the activation energy to cause the chemical reaction to occur.

[0017] As used herein, the term “spiral helix” refers to a helical blade that can be wound around a shaft. A central shaft may be used to form and maintain the helical helix, but this is not required by the process. The winding simply needs to be done without a central hole to cause the process stream to be short-circuited.

[0018] As used herein, the term "linear velocity" refers to the distance that a gas will travel in a given time.

[0019] As used herein, the term "mass flow rate" refers to the mass of a liquid substance passing per unit time. The SI unit is kilograms per second. Mass flow depends directly on the density of the liquid, its velocity, and the area of ​​the cross-section. The mass flow rate can be determined according to the following mathematical formula:

[0020] m=ρVA

[0021] Here, ρ = fluid density, V = liquid velocity, and A = cross-sectional area.

[0022] As used herein, the term “Nusselt number” refers to the ratio of convective to conduction heat transfer at a boundary within a fluid. A Nusselt number of value 1 represents heat transfer by pure conduction. Values ​​between 1 and 10 are characteristic of laminar flow. Larger Nusselt numbers correspond to more active convection, and turbulent flow is typically in the range of 100 to 1000.

[0023] As used herein, the term “radiation furnace” refers to a direct heater or direct-fired heater used to provide thermal energy or heat for a reactor. These are used to provide heat for a process. Radiation furnace designs may vary depending on the type of fuel and the method of introducing combustion air. Heat is generated by mixing the fuel with air or oxygen, or from electrical energy. Residual heat may escape from the furnace as flue gas.

[0024] As used herein, the term "Reynolds number" refers to the dimensionless ratio of inertial force to viscous force in a fluid subjected to relative internal movement due to different fluid velocities. The Reynolds number helps predict flow patterns in different fluid flow situations. At low Reynolds numbers, the flow tends to be dominated by laminar flow, whereas at high Reynolds numbers, the flow tends to be turbulent. When the Reynolds number is less than about 2,000, the flow in a pipe is generally laminar, whereas at values ​​greater than 3,000, the flow is generally turbulent.

[0025] As used herein, the term "volumetric flow rate" refers to the volume of fluid passing through a designated point per unit time. The volumetric flow rate can be determined according to the following mathematical formula:

[0026] Q=AV

[0027] Here, Q is the volumetric flow rate, A is the cross-sectional area occupied by the flowing material, and V is the average flow velocity.

[0028] The present specification discloses an endothermic catalytic reactor apparatus comprising a radiative furnace and a reactor. The radiative furnace includes a burner configured to provide thermal energy to the furnace. The reactor has a reactant inlet and an outlet, is located within the furnace, and is configured to receive radiative thermal energy from the furnace. Within the reactor, there is one or more static helical spirals located within the reactor so that the material may follow a defined path to move from the reactant inlet to the outlet. The helical spirals may be configured to hold a catalyst on their outer surface. One or more inlet ports are located at the inlet portion of the reactor and are configured to receive a reactive starter material. The reactor includes one or more outlet ports on or near the outlet portion configured to discharge a product from the reactor. The reactor is configured to allow the starter material to receive radiative thermal energy and sufficiently interact with the catalyst to cause a reaction to occur that converts the starter material into a product.

[0029] As illustrated in FIG. 1, the reactor device (100) includes an endothermic reactor (105) and a radiant furnace (110) (dotted line) including a flue (108). Reactants are supplied to the endothermic reactor (105) through a reactant supply line (120) and flow through an optional heat exchanger (130) and an optional heat exchanger (180), and can be selectively heated by being emptied into the endothermic reactor (105) at the inlet portion (135) of the reactor (105) (the heat exchangers (130, 180) are optional and can be used depending on the process to be performed within the reactor (105)). As illustrated, the reactant supply line moves through the shell side (182) of the heat exchanger (180), and the material moves in the direction of the arrow (183). The radiant furnace (110) may substantially surround the entire endothermic reactor (105) and may include a burner (140) (shown by a dashed line) capable of burning combustible material from line (145), or alternatively, an electric heating element within the radiant furnace (110).

[0030] The endothermic reactor (105) includes a static helical spiral (150) configured to include a defined path located within the endothermic reactor (105) around a central shaft (107) and to allow reactants to follow the defined path to move from the inlet portion (135) to the product outlet portion (160). The helical spiral (150) has a thickness (157) as described herein. The helical spiral (150) may be configured to include a catalyst on its outer surface, a first surface (162) and a second surface (164). The radiation furnace (105) provides sufficient thermal energy to enable reactants to be converted into products through direct conversion or catalytic reaction through interaction with the catalyst included on the first and second surfaces (162, 164) of the helical spiral (150). The effluent from the product discharge section (160) passes through the tube (184) of the heat exchanger (180) in the direction of the arrow (183) and heats the contents of the reactant on the shell side (182). The reactant can be heated sufficiently to become a gas or vapor state when leaving the heat exchanger (130), and can be heated to near the reaction temperature when leaving the heat exchanger (180) and entering the endothermic reactor (105).

[0031] The flow through the heat exchanger (180) may be reverse flow as illustrated in FIG. 1, where the reactants flow through the reactant supply line (120) in the direction illustrated as the first flow direction (181) and the product stream flows through the product discharge line (160) in the direction illustrated as the second flow direction (182).

[0032] To increase the reaction rate of the process within the reactor (105), a catalyst may be employed as described herein. The catalyst may not alter the maximum conversion at a given temperature. In some cases, given the efficient energy transport involving highly turbulent spiral reactant flow and the elevated temperature achievable by the radiation furnace (110), direct conversion such as acceptable process performance may be obtained without a catalyst.

[0033] The product leaving the tube (184) of the heat exchanger (180) can be separated in a separator (170), which can produce several separated streams, illustrated as an indefinite exemplary stream (172, 174) and an overhead stream (188). One of the streams (172, 174) may be primarily an organic stream, and the other may be an aqueous stream. Non-condensable material can be removed from the separator (170) via the overhead stream (188). When the non-condensable material is combustible material, it may be mixed with other combustible materials or used alone in line (145) and then used in the burner (140) when it is a combustion burner.

[0034] As illustrated in FIG. 2, similar features of FIG. 1 are numbered in the same way, and the reactor device (200) includes an endothermic reactor (105) and a radiator (110) (dotted line) including a flue (108). Reactants are supplied to the endothermic reactor (105) through a reactant supply line (120) and flow through a heat exchanger (130) and an optional heat exchanger (180), and can be selectively heated by being emptied into the endothermic reactor (105) at the inlet portion (135) of the reactor (105). As illustrated, the reactant supply line moves through the shell side (182) of the heat exchanger (180), and the material moves in the direction of the arrow (183). The radiant furnace (110) may substantially surround the entire endothermic reactor (105) and may include a burner (140) (shown by a dashed line) capable of burning combustible material, or alternatively, an electric heating element within the radiant furnace (110).

[0035] The endothermic reactor (105) includes a first static helical spiral (150) and a second helical spiral (152) that may be located within the endothermic reactor (105) around a central shaft (107) and configured to allow reactants to follow a defined path to move from an inlet portion (135) to a product discharge portion (160). The helical spirals (150, 152) may each have a thickness (158, 157) as described herein. The defined path may be configured to include a catalyst on its outer surface, namely the first and third surfaces (162, 166) and the second and fourth surfaces (164, 168), respectively. The radiation furnace (105) provides sufficient thermal energy to enable the reactants to be converted into products through direct conversion or catalytic reaction through interaction with the catalyst contained on the first, second, third, and fourth surfaces (162, 164, 166, 168) of the helical spiral (150, 152). The effluent from the product discharge section (160) passes through the tube (184) of the heat exchanger (180) in the direction of the arrow (183) to heat the contents of the reactants on the shell side (182). The reactants can be heated sufficiently to be in a gaseous or vapor state when leaving the heat exchanger (130), and can be heated to near the reaction temperature when leaving the heat exchanger (180) and entering the endothermic reactor (105).

[0036] The flow through the heat exchanger (180) may be reverse flow as illustrated in FIG. 1, where the reactants flow through the reactant supply line (120) in the direction illustrated as the first flow direction (181) and the product stream flows through the product discharge line (160) in the direction illustrated as the second flow direction (182).

[0037] The product leaving the tube (184) of the heat exchanger (180) can be separated in a separator (170), which can produce several separated streams, illustrated as an indefinite exemplary stream (172, 174) and an overhead stream (188). One of the streams (172, 174) may be primarily an organic stream, and the other may be primarily an aqueous stream. Non-condensable material can be removed from the separator (170) via the overhead stream (188). When the non-condensable material is combustible material, it may be mixed with other combustible materials or used alone in line (145) and then used in the burner (140) when it is a combustion burner.

[0038] As illustrated in FIGS. 1 and 2, spiral flow along a defined path and at high speed against the reactor wall can provide excellent energy transfer between the reactor wall and the reactants regardless of the reactor orientation (vertical, horizontal, or inclined). This wall-to-reactant transfer can be so efficient that the total transfer between the radiation furnace and the reactants may be limited only by the thermal conductivity and thickness of the reactor wall.

[0039] The starting material may pass through a heat exchanger before entering the reactor (105) so that it enters the reactor (105) in a gaseous or vapor state at a temperature of 225°C, e.g. 275°C, 325°C, or 425°C, and may be up to 725°C, such as 675°C or 625°C. The temperature of the starting material entering the reactor (105) may be any value or range between any of the values ​​mentioned above.

[0040] To assist in achieving the desired temperature and flow characteristics while traversing the defined flow path through the reactor (105), the starting material may be mixed with superheated steam before entering the reactor (105).

[0041] The dimensions of the endothermic reactor (105), the defined path through the endothermic reactor (105), the flow rate of reactants or starting materials into the reactor (105), and the flow rate of products out of the reactor (105) can be customized for the specific process to be employed therein. As a non-limiting example, the reactant supply line (120) may be emptied into the reactor (105) through a port that may have any suitable cross-sectional shape, and non-limiting examples are circular, elliptical, square, rectangular, or parallelogram. Other suitable shapes of the reactor (105) include barrel shape or hourglass shape. The cross-sectional area of ​​the port is at least 0.5 m² 2 , for example, 1 m 2 or 2 m 2 It can be up to 6 m 2 , for example, 5 m 2 or 4 m 2 It may be. The cross-sectional area of ​​the port for the starting material entering the reactor (105) may be any value or range between any of the values ​​mentioned above.

[0042] The reactor (105) may be cylindrical and enclosed at both ends. As shown, the reactor (105) may include a static helical spiral as illustrated in FIG. 1 or a static helical spiral having multiple parallel spirals with two parallel spirals as illustrated in FIG. 2. Each end has a port for receiving and discharging a reactant stream. The spiral may extend from an optional central spine to a cylindrical wall. The wall may be made of a metal having a minimum thickness and high thermal conductivity required for stability at the reaction temperature. The reactor (105) is configured to allow the starting material to receive radiant thermal energy and interact sufficiently with the catalyst to cause the reaction to take place, converting the starting material into a product. The helical spiral-reactor wall combination may allow reactant flow at a high velocity, i.e., turbulent, relative to the reactor wall, which may affect energy transport between the wall and the reactant stream.

[0043] The inner diameter of the reactor (105) may be selected based on the specific process to be employed therein. The reactor diameter may be at least 1 m, e.g. 3 m or 4 m, and at most 10 m, e.g. 7 m or 4 m. The diameter of the reactor (105) may be any value or range between any of the values ​​mentioned above.

[0044] In a number of shapes for the reactor (105), the reactor wall may be tapered, which can reduce leakage where the edge of the spiral meets the wall. This configuration is similar to a fitted tapered stopper and reduces leakage compared to one having a straight side.

[0045] When the reactor (105) is in the shape of a barrel or an hourglass, a spiral spiral can be formed first, and then the reactor wall can be wound around the spiral spiral in a “mummy manner.”

[0046] The single spiral shown in FIG. 1 can alternatively be achieved without a central shaft (107). This alternative approach can be used when the width of the spiral surface is wide enough to cover the reactor diameter, thus avoiding a short circuit along the central axis.

[0047] The helical spirals illustrated as 150 and 152 in FIGS. 1 and 2 may take any suitable number of turns, as long as they start at the reactant supply line (120) that supplies the reactant or starting material to the reactor (105) and end at the product discharge section (160). The helical spirals may take at least 1.5 turns, e.g., 2 or 2.5 turns, and up to 6.5 turns, e.g., 5.5, 5, 4.5 turns. The number of turns of the helical spirals may be any value or range between any of the values ​​mentioned above. As will be understood by a person skilled in the art, 0.5 turns place the reactant supply line (120) and the product discharge section (160) on the same side of the reactor (105), whereas a full turn place the reactant supply line (120) and the product discharge section (160) on opposite sides of the reactor (105). The number of rotations of the spiral will vary depending on the process to be employed and the position and orientation of the reactor (105) and associated equipment.

[0048] The width of the helical spiral (150, 152) may be equal to or nearly equal to the inner diameter of the reactor (105) so that there is sufficient fit between the helical edge and the wall of the reactor (105) so that leakage of reactants or starting materials from the desired helical flow (defined path) is minimized.

[0049] The pitch of the helical spiral, illustrated as 150 and 152 in FIGS. 1 and 2, may be any pitch that allows the helical spiral to traverse from a reactant supply line (120) providing reactants or starting materials to a reactor (105) and a product discharge section (160), and may be selected based on a specific process to be employed therein. The pitch of the helical spiral may be at least 0.25 m, e.g. 0.5 m or 0.75 m, and at most 5 m, e.g. 4 m, 3 m or 2 m. The pitch of the helical spiral may be any value or range between any of the values ​​mentioned above.

[0050] The reactor (105), the spiral (150, 152), and other components of the reactor device (100) and the reactor device (200) may be constructed of any material that will be stable in the presence of the process performed therein and will not deteriorate due to the temperature and pressure employed. Non-limiting examples of suitable construction materials include 304 stainless steel, 316 stainless steel, 316L stainless steel, copper, aluminum, alloy A-286, alloy 20, alloy 230, alloy 400, alloy 600, alloy 625, alloy B-2, alloy B-3, alloy C-276, nickel 200, titanium grades 2, 3, 4 and 7, zirconium 702, zirconium 705, and combinations thereof. The walls of the reactor (105) can be made of a material with suitably high thermal conductivity, such as copper or aluminum, so that the walls immediately transfer thermal energy or heat from the furnace to the contents of the reactor (105).

[0051] As shown above, one or more helical spirals illustrated as 150 in FIG. 1 and 150 and 152 in FIG. 2 may be configured to include a catalyst on their outer surface, each illustrated as an upper side (162, 166) and a lower side (164, 168). The specific catalyst will vary depending on the process to be performed within the reactor (105). As a non-limiting example, the catalyst may be deposited on the outer surface and thermally aged; embedding a catalyst containing nanoparticles on the outer surface through a redox reaction at a solid solution interface; embedding the catalyst in a worn, perforated, or rigid mesh material installed on the outer surface; a non-limiting example is supporting the catalyst with a high specific surface area on a stable support material including alumina, silica, zeolite, and carbon—which allows the high specific surface area of ​​the catalyst to be maintained at high catalytic activity—; and other methods known in the art. Regardless of how the catalyst is retained on the external surface, the catalyst will be separated from the defined flow path and will not interfere with it, so as previously described, high volume and high flow rate can be maintained.

[0052] A configuration of a catalyst on a helical helix, where the catalyst is located on the outer surface of the helical helix rather than at a position that obstructs the flow of reactants or starters along a defined flow path, avoids flow resistance and pressure drop arising from the process stream (reactants and / or starters) passing through small gaps or spaces between catalyst particles. In other words, reactants or starters are not allowed to pass through a catalyst bed that obstructs the defined flow path. This configuration provides an unobstructed path for reactants or starters along the defined flow path. This design can enable the achievement of Reynolds numbers and Nusselt numbers that characterize the flow and heat transfer properties described herein.

[0053] The thickness of the spiral helix, illustrated as 157 in FIGS. 1 and 2, may be any thickness that provides sufficient structural integrity to the spiral helix in the desired process but is not thick enough to obstruct heat transfer or defined flow paths. As a non-limiting example, the thickness of the spiral helix may be 0.3 cm, e.g. 1 cm or 2 cm, and up to 5 cm, e.g. 4 cm. The thickness of the spiral helix may be any value or range between the values ​​mentioned above.

[0054] The reactor (105) may include a plurality of helical spirals as illustrated in FIG. 2, where two helical spirals (150, 152) are illustrated. When a plurality of helical spirals are employed, the spacing between one helical spiral and the nearest helical spiral will often be equidistant to provide the most efficient flow along a defined path. The spacing between the helical spirals may not be equidistant, but flow efficiency may be reduced as a result.

[0055] As illustrated in FIG. 2, the product discharge section (160) provides a path for the exit streams from both of the two parallel spirals (150, 152), both of which are discharged into the product discharge section (160) to exit the reactor (105).

[0056] The starting material or reactant may optionally include vapor to achieve desired physical parameters as described below. The ratio of vapor to starting material or reactant may be at least 0.25:1, e.g., 0.5:1 or 0.75:1, and at most 4:1, e.g., 3:1, 2:1 or 1.5:1. The ratio of vapor to starting material or reactant may be any value or range between any of the values ​​mentioned above.

[0057] The pressure within the reactor (105) may be any pressure that facilitates the flow or starting material or reactant along a defined path and promotes the conversion of the reactant into a product. The pressure within the reactor (105) may be at least 0.25 atm, e.g., 0.5 atm or 0.75 atm, and at most 10 atm, e.g., 8 atm, 6 atm, 4 atm or 2 atm. Suitable valves and compressors as known to a person skilled in the art may be employed to achieve and control the desired pressure. The pressure within the reactor (105) may be any value or range between the values ​​mentioned above.

[0058] The starting material and optional steam may have a mass flow rate through the reactor (105) of 20 kg / sec, e.g. 25 kg / sec or 30 kg / sec, and up to 150 kg / sec, e.g. 140 kg / sec or 125 kg / sec. The mass flow rate for the starting material and optional steam flowing through the reactor (105) may be any value or range between any of the values ​​mentioned above.

[0059] The starting material and optional steam may have a volumetric flow rate through the reactor (105) of 500 l / sec, e.g. 600 l / sec or 700 l / sec, and up to 1,000 l / sec, e.g. 900 l / sec or 500 l / sec. The volumetric flow rate for the starting material and optional steam flowing through the reactor (105) may be any value or range between any of the values ​​mentioned above.

[0060] The starting material and optional steam may have a linear velocity through the reactor (105) of 15 m / sec, e.g. 20 m / sec or 25 m / sec, and up to 35 m / sec, e.g. 33 m / sec or 30 m / sec. The linear velocity for the starting material and optional steam flowing through the reactor (105) may be any value or range between any of the values ​​mentioned above.

[0061] The dimensions, the defined path through the endothermic reactor (105), the flow rate of the reactant or starter material into the reactor (105), and the flow rate of the product out of the reactor (105) are designed to achieve specific flow parameters. As a non-limiting example, the starter material may be a gas when entering the reactor (105) and may flow along the defined path so that the starter material may have a Reynolds number of 1,000,000, e.g. 2,000,000 or 3,000,000 and up to 15,000,000, e.g. 12,500,000 or 10,000,000. The Reynolds number for the starter material flowing through the reactor (105) may be any value or range between any of the values ​​mentioned above.

[0062] The aforementioned flow parameters can be achieved when the catalyst configuration is used on the outer surface of the helical spiral, rather than at a location that obstructs the flow of reactants or starters along the defined flow path. As previously mentioned, this configuration avoids the flow resistance and pressure drop resulting from the process stream (reactants and / or starters) passing through the small gaps or spaces between the catalyst particles. In other words, the reactants or starters are not passed through the catalyst bed that obstructs the defined flow path.

[0063] As a non-limiting example, the starting material is a gas when entering the reactor (105) and can flow along a defined path so that the starting material has a nucelle number of 3,000, e.g. 4,000 or 5,000, and can be up to 15,000, e.g. 12,500 or 10,000. The nucelle number for the starting material flowing through the reactor (105) can be any value or range between any of the values ​​mentioned above.

[0064] The radiation furnace (110) included in the reactor device (100) and the reactor device (200) can generate any suitable temperature for the process to be employed therein, which may include a temperature of 350°C, e.g. 400°C or 450°C, and up to 900°C, e.g. 850°C, 800°C or 750°C. The radiation furnace temperature may be any value or range between any of the values ​​mentioned above.

[0065] As shown above, the starting material is a gas when it enters the reactor (105) and can flow along a defined path. Thermal energy or heat from the furnace can be immediately transferred to the contents of the reactor (105), and the high flow rate indicated by the Reynolds number and the Nusselt number provides sufficient and constant turnover on the surface of the helical helix catalyst, allowing the starting material to be converted into a product.

[0066] The conversion of the starting material into a product within the reactor (105) will vary depending on the process and process conditions employed and may be at least 10%, e.g., 25%, 40%, 50%, 60%, 70%, 75%, or 80%, and at most 100%, e.g., 99%, 95%, or 90%. The conversion of the starting material into a product may be any value or range between any of the values ​​mentioned above.

[0067] An outlet stream containing the product, optionally unreacted starter material, optionally non-condensable material, and optional vapor may exit the reactor (105) through line (160) and enter the heat exchanger (180). For ease of explanation, the heat exchanger is shown in a vertical orientation in FIGS. 1 and 2 and is nearly parallel to the reactor (105). Particularly in large-volume applications, the heat exchanger (180) may be in a horizontal orientation. The outlet stream may be directed to the tube side (184) of the heat exchanger (180) flowing in the direction of arrow (183), where it may be used to heat the starter material or reactant transported from the reactant supply line (120) to the shell side (182) of the heat exchanger before entering the inlet portion (135) of the reactor (105). The relative flow pattern between the shell side (182) and the tube side (184) may be in the same direction or opposite or reverse flow directions depending on the process employed. The outlet stream leaves the tube (184) of the heat exchanger (180) and enters the separator (170). The separator (170) separates the outlet stream into several separate streams, illustrated as an indefinite exemplary stream (172, 174) and an overhead stream (188). One of the streams (172, 174) contains mainly an organic stream and the other mainly an aqueous stream. Non-condensable material can be removed from the separator (170) through the overhead stream (188). When the non-condensable material is combustible material, it can be mixed with other combustible materials or used alone in line (145) and then used in the burner (140) when it is a combustion burner.

[0068] Conventional methods, such as distillation towers, can be used to isolate unreacted starter materials or reactants from the product in the organic stream and to isolate unreacted starter materials or reactants from the water in the aqueous stream. The product can then be packaged as appropriate, the unreacted starter materials or reactants can be returned to the reactant supply line (120), and the water can be regenerated into steam or superheated steam and used as described above.

[0069] Accordingly, the present disclosure provides a method for converting reactants into products, the method comprising the steps of: passing reactants through a heat exchanger to provide a heated reactant which may be in a gaseous or vapor state and optionally include superheated steam as described above at a temperature described above; providing the heated reactant to an endothermic catalytic reactor apparatus described above, wherein the endothermic catalytic reactor apparatus comprises a burner as described above and is configured to provide thermal energy or heat to a furnace, and a radiation as described above; a reactor having any configuration described above, having a reactant supply line and a product discharge section, located within a furnace and configured to receive radiant thermal energy or heat from a furnace; one or more static helical spirals located within the reactor so that a material may follow a path defined from the reactor supply line to the product discharge section and configured to hold a catalyst as described above; one or more inlet ports on an inlet section configured to receive reactants from the reactant supply line; and a product discharge port on or near an outlet section configured to discharge the product from the reactor; The reactor is configured to allow the reactants to receive radiant thermal energy and sufficiently interact with the catalyst to cause a reaction to occur that converts the reactants into products; the endothermic catalytic reactor device is configured to optionally isolate one or more optional second combustible materials from the reaction occurring within the reactor and, as described above, to provide one or more optional second combustible materials to the burner, comprising a reactant providing step; and a step of separating the product from the non-product material as described above.

[0070] As will be obvious to a person skilled in the art, the endothermic catalytic reactor apparatus described herein may be used for a number of endothermic processes, non-limiting examples include the decomposition of alkanes, the reaction of thionyl chloride with cobalt(II) sulfate heptahydrate, and thermal decomposition reactions. Non-limiting specific examples may also include the conversion of ethane to ethylene, propane to propylene, ethylbenzene to styrene, ethyltoluene to vinyltoluene, and diethylbenzene to divinylbenzene.

[0071] As a non-limiting detailed example, the present disclosure provides a method for producing styrene, the method comprising the steps of: passing a reactant stream comprising ethylbenzene and optionally superheated steam through a heat exchanger to provide a reactant stream heated as described above at a temperature of 450°C, e.g. 475°C or 525°C and up to 725°C, e.g. 675°C or 625°C; providing the reactant stream to an endothermic catalytic reactor apparatus as described above, wherein the endothermic catalytic reactor apparatus comprises a radiation furnace as described above comprising a burner as described above configured to provide thermal energy to a furnace; and a reactor having any of the configurations described above, having a reactant supply line and a product discharge section, located within a furnace and configured to receive radiant thermal energy or heat from the furnace. One or more static helical helices as described above, comprising a defined path located within a reactor to allow a material to follow a defined path to move from a reactant supply line to a product discharge section, wherein the helical helice may be configured to retain a catalyst on its outer surface as described above; one or more inlet ports on an inlet section configured to receive a heated reactant; and a product discharge section on or near an outlet section configured to discharge a product stream containing styrene from the reactor; the reactor is configured to allow the heated reactant stream to receive radiant thermal energy and sufficiently interact with the catalyst to cause a reaction to occur converting ethylbenzene into styrene and byproduct hydrogen; a reactant stream supply step in which the product stream comprises styrene, hydrogen, optionally unreacted ethylbenzene, and optionally vapor; and a step of separating the product stream into a non-condensing overhead comprising a mainly aqueous phase, a mainly organic phase, and hydrogen. It includes the step of separating styrene from the mainly organic phase as described above and optionally from the mainly aqueous phase as described above.

[0072] As a non-limiting example, when large-scale production of styrene from ethylbenzene is required, the required flow rate is too high to allow flow through tubes filled with catalyst particles, i.e., catalyst beds, as previously described. As previously described, at sufficiently high flow rates, energy transfer can be sufficiently efficient so that any radial temperature and / or concentration gradient is negligible. The reactor design described herein has the spiral flight(s) of the static mixer coated and / or impregnated with catalyst to provide a clean, unhindered, high-speed path for reactant flow.

[0073] As shown above, this wall-to-reactant transfer can be very efficient, so the total transfer between the radiation furnace and the reactants may be limited only by the thermal conductivity and thickness of the reactor wall.

[0074] The conversion of ethylbenzene to styrene may be at least 70%, e.g. 75% or 80%, and at most 100%, e.g. 99%, 95% or 90%. The conversion of ethylbenzene to styrene may be any value or range between any of the values ​​mentioned above.

[0075] As previously mentioned, styrene can subsequently be separated from the product stream.

[0076] The non-condensable hydrogen byproduct can be packaged using methods known in the relevant art field for subsequent use, and non-limiting examples include generating electrical energy that can be used in electric vehicles, fuel cells, batteries, or to supply the energy required when the burner (140) is electric. As another alternative, hydrogen can be used as a combustible material in line (145) when the burner (140) is a combustion burner.

[0077] As indicated above, the endothermic catalytic reactor apparatus and method described in this specification can be used to provide numerous products as described above.

[0078] Although specific embodiments of the present invention have been described for illustrative purposes, it will be obvious to those skilled in the art that numerous variations of the details of the present disclosure may be made without departing from the invention as defined in the appended claims.

Claims

Claim 1 An endothermic catalytic reactor device comprising: a radiant furnace including a burner configured to provide thermal energy to the furnace; a reactor having an inlet portion and an outlet portion, located within the furnace and configured to receive radiant thermal energy from the furnace; one or more static helical helices located within the reactor so that a substance may follow a defined path to move from the inlet portion to the outlet portion, configured to provide an unhindered defined path; one or more inlet ports on the inlet portion configured to receive a reactive starter material; and an outlet port on the outlet portion configured to discharge a product from the reactor; the reactor is configured to allow the starter material to receive radiant thermal energy and sufficiently interact with a catalyst to cause a reaction to occur that converts the starter material into a product, and the reactor does not include a section that creates flow resistance or pressure drop for the reactive starter material along the defined path. Claim 2 An endothermic catalytic reactor apparatus according to claim 1, wherein the starting material is a gas and flows along a defined path such that the starting material has a Reynolds number of 1,000,000 to 15,000,000. Claim 3 An endothermic catalytic reactor apparatus according to claim 1 or 2, wherein the starting material is a gas and flows along a defined path such that the starting material has a nucleus number of 3,000 to 15,000. Claim 4 An endothermic catalytic reactor apparatus according to claim 1 or 2, wherein the starting material passes through a heat exchanger before entering the reactor and enters the reactor at a temperature of 225°C to 725°C. Claim 5 The endothermic catalytic reactor apparatus according to claim 1 or 2, wherein the starting material has a mass flow rate through the reactor of 20 kg / sec to 150 kg / sec. Claim 6 The endothermic catalytic reactor apparatus according to claim 1 or 2, wherein the starting material has a volumetric flow rate through the reactor of 500 l / sec to 1,000 l / sec. Claim 7 An endothermic catalytic reactor apparatus according to claim 1 or 2, wherein the starting material has a linear velocity through the reactor of 15 m / sec to 35 m / sec. Claim 8 An endothermic catalytic reactor device according to claim 1 or 2, wherein the radiation furnace has a temperature of 350°C to 900°C. Claim 9 An endothermic catalytic reactor apparatus according to claim 1 or 2, wherein the conversion of the starting material into a product is at least 10%. Claim 10 An endothermic catalytic reactor apparatus according to claim 1 or 2, wherein the starting material and the product are in the vapor phase when inside the reactor. Claim 11 An endothermic catalytic reactor apparatus according to claim 1 or 2, wherein the product is separated from the non-product material. Claim 12 In paragraph 11, the endothermic catalytic reactor apparatus comprises a non-product material that is combustible in a burner. Claim 13 A method for converting reactants into products, comprising the steps of: passing reactants through a heat exchanger to provide reactants heated at a temperature of 225°C to 725°C; and providing the heated reactants to an endothermic catalytic reactor device, wherein the endothermic catalytic reactor device comprises: a radiative furnace including a burner configured to provide thermal energy to a furnace; a reactor having an inlet section and an outlet section, located within the furnace and configured to receive radiative thermal energy from the furnace; one or more static helical helices located within the reactor to allow a material to follow a defined path from the inlet section to the outlet section, configured to provide an unhindered defined path; one or more inlet ports on the inlet section configured to receive reactants; and an outlet port on the outlet section configured to discharge a product from the reactor; wherein the reactor is configured to allow the reactants to receive radiative thermal energy and sufficiently interact with a catalyst to cause a reaction to occur that converts the reactants into products, and the reactor does not include a section that creates flow resistance or pressure drop for the reactive starting material along the defined path, wherein the step of providing reactants A method comprising the step of separating a product from a non-product material. Claim 14 In paragraph 13, the reactant is a gas and flows along a defined path such that the reactant has a Reynolds number of 1,000,000 to 15,000,000. Claim 15 A method according to claim 13 or 14, wherein the reactant is a gas and flows along a defined path such that the reactant has a nucleus number of 3,000 to 15,000. Claim 16 The method of claim 13 or 14, wherein the reactant has a mass flow rate through a reactor of 20 kg / sec to 150 kg / sec. Claim 17 A method for producing styrene, comprising the steps of: passing a reactant stream containing ethylbenzene through a heat exchanger to provide a reactant stream heated at a temperature of 450°C to 725°C; providing the reactant stream to an endothermic catalytic reactor device, wherein the endothermic catalytic reactor device comprises: a radiant furnace including a burner configured to provide thermal energy to a furnace; a reactor having an inlet portion and an outlet portion, located within the furnace and configured to receive radiant thermal energy from the furnace; one or more static helical helices including a defined path located within the reactor so that a material may follow a defined path from the inlet portion to the outlet portion, one or more static helical helices configured to provide an unhindered defined path; one or more inlet ports on the inlet portion configured to receive the heated reactant stream; and an outlet port on the outlet portion configured to discharge a product stream containing styrene from the reactor; A reactor is configured to allow a heated reactant stream to receive radiant thermal energy and sufficiently interact with a catalyst to cause a reaction to occur converting ethylbenzene into styrene and byproduct hydrogen, wherein the reactor does not include a section that creates flow resistance or pressure drop for the reactive starting material along a defined path; a step of providing a reactant stream in which the product stream comprises styrene and hydrogen; a step of separating the product stream into an aqueous phase, an organic phase and a non-condensing overhead comprising hydrogen; and a step of separating styrene from the organic phase. Claim 18 In paragraph 17, the heated reactant stream is a gas and flows along a defined path such that the reactant stream has a Reynolds number of 1,000,000 to 15,000,000 and a Nusselt number of 3,000 to 15,000. Claim 19 A method according to claim 17 or 18, wherein the conversion of ethylbenzene to styrene is at least 70%. Claim 20 A method according to paragraph 17 or 18, wherein styrene is separated from the product stream. Claim 21 Styrene produced according to the method of paragraph 17 or 18. Claim 22 delete Claim 23 delete Claim 24 delete

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