Radial flow reactor in particular for synthesis of methane and / or methanol and method for operating the radial flow reactor

Abstract

The present disclosure relates to a radial flow reactor (1) and to a method of operating the radial flow reactor (1). The radial flow reactor (1) comprising an inflow channel (2), extending along a longitudinal axis (L), the inflow channel (2) being configured to enable reactants (10) to stream into the radial flow reactor (1), a plurality of synthesis channels (3) extending radially with respect the longitudinal axis (L) starting from the inflow channel (2), thereby fluidically connecting the inflow channel (2) with the respective synthesis channel (3), the plurality of synthesis channels (3) comprising a structured fixed-bed catalyst (31) and a pressure-setting element (5) arranged in the flow path of the radial flow reactor (1) and configured to set the pressure of the reactants (10) through the plurality of synthesis channels (3) during operation of the radial flow reactor (1).

Description

[0001] RADIAL FLOW REACTOR IN PARTICULAR FOR SYNTHESIS OF METHANE AND I OR METHANOL AND METHOD FOR OPERATING THE RADIAL FLOW REACTOR

[0002] FIELD OF THE DISCLOSRE

[0003] The present disclosure relates to a radial flow reactor used in an exothermic reaction, in particular for the synthesis of methane and / or methanol in an exothermic reaction. Further, the present disclosure relates to a method of operating of the radial flow reactor for synthesis of methane and / or methanol in an exothermic reaction and a method of synthesizing methane and / or methanol in an exothermic reaction.

[0004] BACKGROUND OF THE DISCLOSURE

[0005] The synthesis of methane (methanation) from CO2 (as well as CO) is a strongly exothermic reaction that requires efficient heat removal from the reaction zone, particularly when carried out catalytically with short reaction times. Conventionally, random fixed-bed reactors are used for the synthesis of methane. The random fixed-bed reactor comprises a catalyst pellet bed, in which the synthesis of methane from CO2 and / or CO is performed. The catalyst pellets are conventionally arranged randomly unstructured and may move freely. The pellet bed of the random fixed-bed reactor defines the reactor zone.

[0006] An alternative to the random fixed-bed reactors are structured fixed-bed reactors with a plurality of channels, which comprise a catalyst coating. These reactors comprise a solid body structure, which define the channels. The reactants stream through the channels and react in the channels with the catalyst coating. The reaction zone is therefore within the channels. For example, the document DE 10 2016 125 641 A1 discloses a process for production of a natural gas substitute from hydrogen-containing gas mixtures using a reactor with channels.

[0007] Regardless of the reactor type employed, the strongly exothermic nature of methane synthesis requires careful control of the heat removal from the reaction zone for controlling the temperature inside the reactor zone. Heat removal of the reaction zone is particularly critical and challenging for structured fixed-bed catalysts. Controlling of the temperature inside the reactor zone is important for ensuring a high quality and high purity product and for ensuring high yields of target product. In particular, the chemical equilibrium of the different chemical reactions taking place is temperature dependent. Typically, it is desirable to maintain the temperature within a narrow target temperature range, in which the balance between high product yield, high product purity and a fast reaction is advantageous.

[0008] A particular challenge arising from known reactor configurations, is the required building space of the entire reactor and its supply lines and components in dependence of the reactor capacity. The extensions of the pellet bed of random fixed bed reactors mainly determines the dimensions of the respective reactor and its production capacity. The pellet bed of such reactors may be enlarged in order to increase the output of the reactor. The geometrical structure of structured fixed bed reactors is more complicated and not scalable as simply as with the random fixed bed reactors. The catalyst of structured fixed bed reactors are e.g. arranged in tubes, typically with fixed dimensions. Increasing the output of a reactor using such tubes requires arranging a plurality of such tubes in parallel, such that the reactants may stream through the catalyst. The overall structure and arrangement of the different components of the structured fixed reactors is more complex and not yet solved in a sophisticated manner. Structured fixed bed reactors have not yet been industrialized so far. As a result, there is a need to advance the state of the art with respect to the overall structure of structured fixed bed reactors for synthesis of methane and / or methanol in an exothermic reaction.

[0009] The disclosure of the Swiss patent application with the application number CH000241 / 2023 of the same applicant and the Swiss patent application with the application number CHO01303 / 2023 of the same applicant is hereby incorporate by reference in its entirety.

[0010] SUMMARY OF THE DISCLOSURE

[0011] It is an object of the present disclosure to provide a radial flow reactor for exothermic reactions, in particular for a synthesis of methane and / or methanol in an exothermic reaction, and a method for operating of said radial flow reactor, in particular of synthesizing methane and / or methanol in an exothermic reaction. In particular, it is an object of the present disclosure to provide a radial flow reactor for exothermic reactions and a method for operating of said radial flow reactor, which address at least some of the disadvantages of the prior art. Advantageously, it is an object to provide a radial flow reactor enabling to set the pressure of the reactants streaming into a plurality of synthesis channels.

[0012] According to the present disclosure, these objects are addressed by the features of the independent claims. In addition, advantageous embodiments follow from the dependent claims, figures and the description.

[0013] According to the present disclosure, a radial flow reactor for a synthesis is specified. The radial flow reactor is in particular configured for a synthesis of methane and / or methanol in an exothermic reaction. The radial flow reactor extends along a longitudinal axis and comprises preferably an inflow channel, a plurality of synthesis channels and at least one pressure-setting element.

[0014] The inflow channel extends along the longitudinal axis and is configured to enable reactants of the synthesis to stream into the radial flow reactor in longitudinal direction. The inflow channel is the components of the radial flow reactor, along which the reactants of the synthesis stream into the radial flow reactor.

[0015] The plurality of synthesis channels are configured for the synthesis and extend radially with respect the longitudinal axis starting from the inflow channel. The synthesis channels are fluidically connected to the inflow channel such that the reactants stream from the inflow channel through the synthesis channels during operation of the reactor. Each of the synthesis channels further comprise a structured fixed-bed catalyst, which enables the synthesis to take place during operation of the radial flow reactor. Radial extension with respect to the longitudinal axis means that the main extension direction of the plurality of synthesis channels is arranged radially, perpendicular to the longitudinal axis. It is not required that the plurality of synthesis channels only extend radially, a partial inclination or curved extension would also be conceivable. The synthesis channels are the channels of the radial flow reactor in which the synthesis, in particular the exothermic reaction, takes place during operation. The structured fixed bed catalyst arranged in each of the synthesis channels provides the required conditions for the synthesis. The reactants stream through the synthesis channels, in particular through the structured fixed bed catalyst, thereby reacting to form the products of the synthesis, in particular methane and / or methanol. In order to enable a uniform synthesis across all of the synthesis channels, it is important to provide uniform synthesis parameters within all of the synthesis channels. The different synthesis channels may be arranged at different axial or circumferential positions with respect to the streaming directions or may have slightly varying pressure drop parameters, which may affect the synthesis in a negative manner. Radial flow velocities that are too high lead to high temperatures, while flow velocities that are too low lead to a low product yield. As a result, some synthesis channels can be "thermally overloaded" and in others, the reaction does not even ignite. The pressuresetting element of the radial flow reactor is configured to address this issue, and is in particular configured to uniformly distribute the pressure of the reactants streaming into each of the structured fixed-bed catalyst of the plurality of synthesis channels.

[0016] The pressure-setting element is configured to set the pressure and / or pressure drop of the reactants through the plurality of synthesis channels. The pressure-setting element is e.g. a separate or integrated mechanical component e.g. a valve, which is configured to set or control the pressure of the reactants, in particular the fluid comprising the reactants, from the inflow channel to the structured fixed-bed catalyst in the synthesis channel. The term pressure may include in this context pressure drop and pressure profile of the reactants and / or products through the synthesis channels. The pressure-setting element is e.g. arranged at least partially in the inflow channel and / or at least partially in the synthesis channel. One of the pressure setting elements may be arranged in the inflow channel covering a plurality of openings to the respective synthesis channels. In another embodiment, each synthesis channel comprises a single respective pressuresetting element. The pressure-setting element enables that the pressure of the reactants, is set accordingly or is controlled respectively such that in each of the synthesis channels the required synthesis parameter may be reached for an advantageous synthesis during operation of the radial flow reactor. In some variants, the pressure-setting element is a pressure-dropping element. In other words, in these variants, the pressure is typically decreased or maintained, but typically not increased.

[0017] In an embodiment, the pressure setting element is arranged in the flow path of the reactants, in particular in the flow path of the radial flow reactor, upstream of the structured fixed-bed catalysts, in particular within the respective synthesis channels. Alternatively or additionally the pressure setting element is arranged in the flow path of the products downstream of the structured fixed-bed catalysts, in particular within the respective synthesis channels. In other words, the pressure setting element is arranged in the flow path of the radial flow reactor for the reactants and the products of the synthesis.

[0018] In an embodiment, the pressure-setting element is selected for at least one, preferably for each, of the plurality of synthesis channels such that a uniform pressure or pressure drop through the plurality of the synthesis channels arranged along the longitudinal axis is provided. The uniform pressure or pressure drop ensures that the flow velocity of the reactants through the structured fixed bed is also uniform, thereby advantageously increasing the yield of the synthesis. It is e.g. conceivable that the different synthesis channels e.g. arranged at different axial positions have different pressure setting elements arranged upstream or downstream of their structured fixed-bed catalyst such that the pressure through all of the synthesis channels is uniform.

[0019] In an embodiment, at least two of the plurality of synthesis channels are arranged at different axial positions, different axial offset positions, with respect to the longitudinal axis. For example, at least two synthesis channels may be offset along the longitudinal direction. Different axial positions of the synthesis channels and therefore of the openings in the inflow channels to the synthesis channels may result in a slightly different pressure of the reactants streaming through the synthesis channels. The larger the axial distance, the larger the resulting pressure difference may be. The pressure is higher closer to the input opening of the inflow channel and will slightly reduce until reaching the last opening to the last synthesis channel with respect to the flow direction within the inflow channel. The structured fixed bed catalyst is preferably the same within each of the synthesis channels, which might require to adapt the pressure-setting element, such that the pressure is uniformly distributed within the plurality of synthesis channels. In an embodiment, the pressure-setting element may be configured to actively control the pressure of the reactants streaming into the respective synthesis channel. An actuator may change the available streaming cross-sectional area of the pressure setting element to actively control the reactant stream. It is also conceivable that some synthesis channels may be blocked and others remain open. In an embodiment, the pressuresetting element is configured to passively control the pressure of the reactants streaming into the respective synthesis channel. For example, a change in pressure may in some variants be effected with no active control.

[0020] In an embodiment, the pressure-setting element comprises a wire screen material, a perforated plate and / or a sintered metal plate. The screen or the plates are relatively simple mechanical components, which provide the required pressure valve functionality of the pressure-setting element. The screen or plates have e.g. a known pressure drop characteristic for the respective reactants. By arranging the respective screen of plate e.g. upstream of the structured fixed bed catalyst, it is possible to uniformly distribute the pressure within the respective plurality of synthesis channels. Further, different screens or plates providing different pressure properties may be arranged upstream or downstream of the respective synthesis channels for enabling a uniform distribution and for compensation e.g. for different axial positions of the synthesis channels. In an embodiment, the pressure setting element provides an available streaming cross-sectional area through the pressure setting element, which is 25 % or less, preferably 10 % or less, even more preferably 5 % or less of the available streaming cross-sectional area through the synthesis channel or through the structured fixed-bed catalyst within the synthesis channel. The pressure setting element is preferably catalytically inactive. The thickness of the pressure setting element is preferably in a range from 1 mm to 200 mm, preferably from 2 mm to 100 mm even more preferably from 4 mm to 50 mm. In a variation, the pressure setting element may comprise a plurality of uniformly distributed openings or uniformly distributed channels. In an embodiment, each of the plurality of synthesis channels comprises the pressure setting element arranged e.g. upstream or downstream of the structured fixed-bed catalyst, within the respective synthesis channel. According to this embodiment, each of the synthesis channels comprises the structured fixed-bed catalyst and upstream the respective pressure setting element, in particular the screen or plate. Positioning all of the pressure setting elements within the synthesis channels enables to advantageously assemble the entire radial flow reactor.

[0021] According to a further embodiment, the radial flow reactor comprises an outflow channel, extending along the longitudinal axis at least partially around or within the inflow channel with a predetermined distance to the inflow channel, thereby forming an intermediate space between the inflow channel and the outflow channel, the intermediate space being bridged by the plurality or synthesis channels, wherein the outflow channel is configured to collect the synthesis products and to enable the synthesis product to stream out of the radial flow reactor in particular in longitudinal direction. In other words, the outflow channel is fluidically connected to the synthesis channel, the outflow channel is in particular arranged downstream of the plurality of the synthesis channels and is configured to collect the synthesis product, in particular the methane or methanol. In case the inflow channel is arranged centrally within the synthesis channels, the outflow channel is arranged around the synthesis channels and the inflow channel. In case the inflow channel is arranged around the synthesis channels, the outflow channel is arranged within the inflow channel. Both configurations are conceivable.

[0022] According to an embodiment, the intermediate space advantageously provides the required distance between adjacent synthesis channels for an advantageous synthesis.

[0023] In an embodiment, the available streaming cross-sectional area of the outflow channel is at least 1 / 2 or at least 3 / 5 of the available streaming cross-sectional area of the inflow channel. The volume of the products of the synthesis of methane is 3 / 5 of the volume of the reactants in case of a 100% conversion rate and the volume of the products of the synthesis of methanol is1 / 2 of the volume of the reactants in case of a 100% conversion rate. In order to avoid a bottleneck at the outflow side, the available streaming cross- sectional area of the outflow channel should be at least three fifths or one half of the available streaming cross-sectional area of the inflow channel respectively.

[0024] In an embodiment, the intermediate space is configured to enable a coolant to stream along the intermediate space and around the synthesis channels for cooling of the structured fixed-bed catalyst arranged in each of the plurality of synthesis channels. The coolant is e.g. a gas or a fluid, in particular a coolant oil or cooling water / oil mixture. The intermediate space preferably has a channel shape and extends in axial direction between the inflow channel and the outflow channel. The radially arranged synthesis channels extend across the intermediate space and produce the heat in the exothermic reaction during the radial flow reactor. This heat needs to be removed. The intermediate space offers an advantageous cooling space. The coolant may stream in longitudinal direction along the intermediate space flowing around the synthesis channels for an optimized cooling of the synthesis channels.

[0025] The radial flow reactor is e.g. determined in that the reactants for the synthesis, the resulting product of the synthesis and the coolant stream mainly in axial direction, mainly parallel with respect to the longitudinal axis. Only the synthesis channels are arranged radially, the exothermic reaction takes place along the radially arranged synthesis channel.

[0026] In an embodiment a plurality of the synthesis channels are arranged at the same axial position with respect to the longitudinal axis, preferably uniformly distributed in circum- ferential direction, thereby forming at least virtually a radial flow reactor segment comprising the plurality of synthesis channels. In other words, the radial flow reactor segment comprises a portion of the inflow channel and a respective number of synthesis channels, which extend from the portion of the inflow channel radially. The radial flow reactor segment is advantageously stackable thereby forming the entire inflow channel and optionally the intermediate space and the outflow channel. The radial flow reactor is advantageously simply manufacturable when using a plurality of radial flow reactor segments is used. In a further embodiment, the different radial flow reactor segments are arranged at a different angel with respect to each other such that an advantageous cooling is enabled. Further, the different radial flow reactor segments may comprise different numbers of synthesis channels, or synthesis channels having different parameters like dimensions. Further, the different synthesis channels may also comprise different structured fixed bed catalysts with different parameters (number of channels, length etc).

[0027] In an embodiment, a quantity of synthesis channels per radial flow reactor segment is selected based on at least one of: the minimum required radial dimension of the structured fixed-bed catalyst, a ratio between length of the structured fixed-bed catalyst and radial dimension of the structured fixed-bed catalyst, the minimum required axial dimension of the synthesis channel, the minimum required coolant flow surface per radial flow reactor segment, at least one radial dimension of the inflow channel, or the dimensions of the outflow channel. The quantity or number of synthesis channels per radial flow reactor segment, in particular per virtual radial flow reactor segment, is selected in order to increase a packaging density of the structured fixed-bed catalyst and at the same time to keep the required installation volume of the radial flow reactor segment as little as possible without affecting the cooling requirements. The dimensions, in particular radial and axial dimensions, of the structured fixed bed catalyst is normally given, because it may e.g. be a standard part. The quantity of the structured fixed bed catalyst determines the dimensions of the radial flow reactor segment and therefore the dimensions of the entire radial flow reactor.

[0028] In an embodiment, the quantity or number of synthesis channels per radial flow reactor segment is in a range from 5 to 25, preferably in a range from 8 to 20, more preferably in a range from 10 to 18, in case the ratio between the length of the structured fixed-bed catalyst to the radial dimension, in particular the diameter, of the structured fixed-bed catalyst is in a range from 2 to 3. The given ranges according to this embodiment determine an optimum with respect to packaging density of the structured fixed bed catalysts and dimensions, in particular diameter, of the radial flow reactor segment. The ratio between the length of the structured fixed-bed catalyst to the radial dimension, in particular the diameter, of the structured fixed-bed catalyst, being in a range from 2 to 3 describes e.g. that the structured fixed bed catalyst is two to three times longer as its diameter.

[0029] In an embodiment, at least one, preferably all, of the plurality of synthesis channels additionally extend partially in axial direction with respect to the longitudinal axis, such that the at least one, preferably all, of the plurality of synthesis channels are arranged inclined with respect to the longitudinal axis. This embodiment might further increases the packaging density of the synthesis channels within the radial flow reactor.

[0030] In an embodiment, the inflow channel, the synthesis channel and / or the outflow channel have at least partially a circular cylindrical shape, a rectangular cylindrical shape, a squared cylindrical shape or a polygonal cylindrical shape. Other shapes or a combination of shapes are of course also conceivable. E.g. the centrally arranged inflow channel may have a circular cylindrical shape, the synthesis channels extending radially from the inflow channel may have a polygonal shape with the polygonal shaped structured fixed bed catalysts and the polygonal shaped pressure setting element arranged within, and the outflow channel surrounding the inflow channel and the channel may have a squared annulus shape.

[0031] In an embodiment, the structured fixed-bed catalyst extends within the respective synthesis channels along its longitudinal axis of the synthesis channel from an inlet end to an outlet end structured fixed-bed catalyst and comprises a plurality of adjacently arranged channels extending preferably from the inlet end to the outlet end structured fixed-bed catalyst. Optionally, a thermal bridge element is arranged at least partially within the structured fixed-bed catalyst. The thermal bridge element is thermally conduc- tively connected to the structured fixed-bed catalyst and extends along the longitudinal axis from an inlet section of the structured fixed-bed catalyst to a downstream section of the structured fixed-bed catalyst, such that during operation at least some reaction heat generated in the inlet section is transferred away from the inlet section.

[0032] Depending on the application, the thermal bridge element may in some variants primarily serve to transfer heat away from the inlet section in order to minimize or even fully prevent hotspots in the inlet section. In some variants, the thermal bridge element may additionally serve to optimize temperature profile in the reactor. For example, by transferring heat from the inlet section to a downstream section of the reactor, the thermal bridge element may contribute to a uniformly distributed mean temperature in the reactor. The structured fixed-bed catalyst may be virtually separated in an inlet section, comprising the inlet end, a downstream arranged middle section and a further downstream arranged outlet section, comprising the outlet end. Depending on the application, the structured fixed-bed catalyst may be a solid state catalyst.

[0033] The thermal bridge element may further be arranged in areas of expected thermal hotspots within the synthesis channels. Arranging the thermal bridge elements in these areas prevents the heat release during operation at the expected hotspots (e.g. in the radial center of the synthesis channels), which helps to have a uniformly distributed temperature profile during operation. Further, the heat released or generated around the expected hotspot is advantageously removable from this area by the thermal bridge element.

[0034] In some variants, the thermal bridge element comprises a rod, in particular a metal rod, extending parallel with respect to the longitudinal axis. For example, the thermal bridge element may consists of a single rod extending parallel with respect to the longitudinal axis. In some variants, the thermal bridge element may comprise or consist of a plurality of rods, in particular metal rods, wherein at least one or even all of the rods may extend parallel with respect to the longitudinal direction. Depending on the application, the thermal bridge element may in some variants comprise at least one lateral protrusion extending radially from a longitudinal main body of the thermal bridge element.

[0035] For example, the thermal bridge element may be made of steel, copper or aluminum. In some variants, the thermal bridge element has a thermal conductivity of at least 5 W / mK, preferably of at least 10 W / mK, more preferably of at least 15 W / mK. In some variants, the thermal bridge element has a thermal conductivity of at least 20 W / mK, for example from 20 W / mK to 300 W / mK. In some variants, the thermal bridge element has a thermal conductivity from 100 W / mK to 300 W / mK. In further variants, the thermal bridge element has a thermal conductivity from 20 W / mK to 100 W / mK. Depending on the application, the reactor may comprise one thermal bridge element or the reactor may comprise two or more, for example from two to ten, thermal bridge elements.

[0036] The radial flow reactor is in particular configured for the synthesis of methane and / or methanol in an exothermic reaction, preferably for the synthesis of methane. Typically, the methanation is carried out at a preferred temperature in a range from 150 °C to 500 °C, preferably in the range from 200°C to 450°C. Maximum temperatures within the reactor may reach 350 °C to 450 °C.

[0037] In a typical embodiment, the structured fixed-bed catalyst is configured for catalytic conversion of the reactants to the product, in particular to methane and / or methanol. In an embodiment, the structured fixed-bed catalyst comprises a body structure. The body structure itself may for example be the catalyst. In other words, the body structure itself may be catalytically active. In another embodiment, the body structure is coated with a catalytically active layer. In this embodiment, the body structure provides the desired surface area for the reaction, but the coating provides the catalytic functionality. The catalytically active material, for example the coating or the body structure itself, comprises for instance a washcoat, which comprises for instance porous aluminum oxide for a surface increase, and the catalytically active substances. The catalytically active substances are for example based on nickel, platinum, rhodium and / or palladium or a combination thereof. In case of coating, the coated body structure, the carrier, may be formed out of or comprises aluminum oxide (AI2O3). The body structure may for example made of a temperature resistant ceramics like cordierite or preferably metals.

[0038] In an embodiment, the reactor comprises a plurality of structured fixed-bed catalysts, which are arranged in series with respect to each other, in particular within the plurality of synthesis channels.

[0039] In a variant, the structured fixed-bed catalyst comprises a main body forming the plurality of adjacently arranged channels. The channels are typically configured to enable reactants to flow through the main body during operation of the reactor. Depending on the application, the channels may be through-going. Typically, each of the channels extends continuously from the inlet section to the outlet section. Depending on the application, the number of channels may vary. For example, in some variants, the structured fixed- bed catalyst may include a plurality of at least 100 channels, each extending from the inlet end to the outlet end. In some variants, the number of channels is for example in a range from 100 to 1000, preferably in a range from 250 to 450. The channels advantageously increase the available surface within the catalyst for an advantageous synthesis. The channels have for example a circular, an angular, a rectangular, a squared and / or a honeycomb shape. Depending on the application, the channels may have different geometries. In some variants, each channel of the structured fixed-bed catalyst has a maximal radial extension from 0.2 mm to 5 mm, preferably from 0.3 mm to 3 mm. The maximal radial extension of the channel may for example be a channel diameter. Typically, two adjacent channels are separated from each other by at least a portion of a catalyst wall. The catalyst wall has a wall thickness.

[0040] In an embodiment, each of the synthesis channels may comprise an outer synthesis channel wall. Typically, the structured fixed-bed catalyst is arranged within the outer synthesis channel wall, preferably coaxially. The outer synthesis channel is e.g. configured that the coolant streaming along the intermediate space streams around the synthesis channel. However, it is also possible that multiple synthesis channels may share an outer synthesis channel wall.

[0041] In a further embodiment, the synthesis channels may comprises a contact body, which is arranged between the structured fixed-bed catalyst, in particular between the catalyst body wall, and the outer synthesis channel wall. The contact body is configured to contact both parts for transferring heat from the catalyst to the outer synthesis channel wall during operation of the radial flow reactor. The contact body may completely surrounds the at least one structured fixed-bed catalyst. The contact body is e.g. made of a corrugated sheet metal and contacts with first contact portions the structured fixed-bed catalyst and with second contact portions the outer synthesis channel wall. The contact body further may comprise a contact body coating, which comprises catalytically active materials such that a bypass flow of reactants streaming along a gas gap between the outer synthesis channel wall and the structured fixed-bed catalyst during operation of the reactor also contact the contact body coating, thus catalyzing the chemical transformation of the reactants. The contact body is preferably fixedly arranged within the synthesis channel e.g. by an adhesive joint, for example a soldering seam or a welding seam, which extends axially or in circumferential direction (or in both directions, like a helix). The adhesive joint further advantageously increases the heat transfer between the different parts.

[0042] In a further aspect, the present disclosure relates to use of the radial flow reactor according to any one of the embodiments disclosed herein for synthesis of methane and / or methanol in an exothermic reaction.

[0043] According to a further aspect, a radial flow reactor assembly is specified. The radial flow reactor assembly comprises a plurality of radial flow reactors as described above and hereinafter, wherein at least two of the plurality of radial flow reactors are arranged such that their respective longitudinal axis are arranged parallel with respect to each other. In other words, at least two radial flow reactors are arranged next to each other forming the radial flow reactor assembly. The plurality of radial flow reactors may share some components, e.g. a portion of the inflow channel, a portion of the outflow channel, a portion of the intermediate space. In addition, the plurality of radial flow reactors in particular its switchable components are e.g. controlled by a single control unit in combination. The radial flow reactor assembly advantageously provides a simple and reliable possibility to up scale the radial flow reactor, in particular their output, and to reduce manufacturing and operating costs by using shared components. In an embodiment, the plurality of radial flow reactors are at least partially surrounded by an outer reactor wall, which preferably has a rectangular, squared cylindrical shape or a circular cylindrical shape. It is conceivable that a plurality of radial flow reactors share one outflow channel. The outflow channel may be formed by a plurality of inner output walls, each of which surround one of the radial flow reactors, and by the singly outer reactor wall, which surround the plurality of radial flow reactors. According to this embodiment, the product of the plurality of radial flow reactors is advantageously collectable by a single outflow channel.

[0044] According to a further aspect, a container is specified. The container comprises at least one of the radial flow reactor as described above or hereinafter and / or comprises at least one radial flow reactor assembly as described above or hereinafter. The container is e.g. a standard shipping container having e.g. standardized dimensions is used for positioning and / or housing of the radial flow reactor or the radial flow reactor assembly. A standard shipping container offers advantageous transportation possibilities. Further, it is advantageously possible to stack or to arrange a plurality of containers next to each other on site.

[0045] According to a further aspect, a method of operating a radial flow reactor for synthesis in particular of methane and / or methanol in an exothermic reaction, is specified.

[0046] In a first step a radial flow reactor as described above and / or hereinafter, a radial flow reactor assembly as described above or hereinafter or a container as described above or hereinafter is specified.

[0047] In a second step, the radial flow reactor is operated by inducing into the radial flow reactor in particular in the inflow channel, the reactants. It is to be understood that both the foregoing general description and the following detailed description present embodiments, and are intended to provide an overview or framework for understanding the nature and character of the disclosure. The accompanying drawings are included to provide a further understanding, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments, and together with the description serve to explain the principles and operation of the concepts disclosed.

[0048] BRIEF DESCRIPTION OF THE DRAWINGS

[0049] The present disclosure will be more fully understood from the detailed description given herein below and the accompanying drawings, which should not be considered limiting to the disclosure described in the appended claims. The drawings are showing:

[0050] Fig. 1 a perspective view of a radial flow reactor according to a first embodiment;

[0051] Fig. 2 a perspective view of a radial flow reactor according to a second embodiment;

[0052] Fig. 3 a perspective view of a radial flow reactor according to a third embodiment;

[0053] Fig. 4 a first longitudinal section view of the radial flow reactor according to a first embodiment;

[0054] Fig. 5 a second longitudinal section view of the radial flow reactor according to a second embodiment;

[0055] Fig. 6 a third longitudinal section view of the radial flow reactor according to a third embodiment;

[0056] Fig. 7 three cross sections through the radial flow reactor, in particular a radial flow reactor segment, showing different arrangement embodiments of the synthesis channels; Fig. 8 another embodiment of the radial flow reactor 1 , in particular of a radial flow reactor assembly;

[0057] Fig. 9 a first embodiment of the radial flow reactor assembly;

[0058] Fig. 10 a second embodiment of the radial flow reactor assembly;

[0059] Fig. 11 a container in particular a standard shipment container comprising the radial flow reactor assembly, according to a first embodiment;

[0060] Fig. 12 a detailed a cross section through a synthesis channel according to a first embodiment;

[0061] Fig. 13 a detailed longitudinal section through the synthesis channel 3 according to the first embodiment;

[0062] Fig. 14 two perspective views of a contact body according to respective embodiments;

[0063] Fig. 15 a plurality of possible embodiments of the pressure setting element;

[0064] Figs. 16 - 18 diagrams showing different parameters for the radial flow reactor;

[0065] Fig. 19 a flow diagram schematically indicating the method steps of the method of operating the radial flow reactor.

[0066] DESCRIPTION OF THE EMBODIMENTS

[0067] Reference will now be made in detail to certain embodiments, examples of which are illustrated in the accompanying drawings, in which some, but not all features are shown. Indeed, embodiments disclosed herein may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Whenever possible, like reference numbers will be used to refer to like components or parts. Figure 1 shows a radial flow reactor 1 according to a first embodiment. The radial flow reactor 1 extends along a longitudinal axis L. The radial flow reactor 1 comprises an inflow channel 2 and a plurality of synthesis channels 3. The inflow channel 2 extends along the longitudinal axis L and is configured to enable reactants 10 to stream into the radial flow reactor 1. The reactants 10 stream along the longitudinal axis L until they reach the openings in the inflow channel 2, which lead to the synthesis channels 3. According to the embodiment shown in Figure 1 , the radial flow reactor 1 comprises eight synthesis channels 3 arranged in circumferential direction around the longitudinal axis L. The eight synthesis channels 3 are distributed uniformly around the inflow channel 2. Figure 1 further indicates by the dotted lines a structured fixed bed catalyst 31 arranged in each of the synthesis channels 3. The structured fixed bed catalyst 31 comprises the catalytic reactive material, which enables that the synthesis takes place during operation of the radial flow reactor 1 . Each of the synthesis channels 3 further comprise a pressure setting element 5, which is arranged upstream of the structured fixed-bed catalyst 31 and downstream of the opening in the inflow channel 2. The pressure setting element 5 is configured to set the pressure of the reactants 10 streaming through the plurality of the synthesis channels 3 during operation of the radial flow reactor 1 . The pressuresetting element 5 is in particular configured to enable a uniform pressure distribution of the reactants through the plurality of synthesis channels 3. Figure 1 further indicates that products 11 , in particular methane and / or methanol stream radially out of the synthesis channels 3. The radial flow reactor 1 as shown in Figure 1 may also be classified as a radial flow reactor segment 15. According to another embodiment, the pressure-setting element 5 might be arranged in the inflow channel 2, preferably on the wall of the inflow channel 2 covering a plurality of openings of the inflow channel 2 to the synthesis channels 3. The pressure-setting element 5 might be in its simple’s embodiment the opening towards the synthesis channel 3 itself. The opening, in particular the size of the opening might be designed such that it sets the pressure for the reactants 10 through the synthesis channels 3. The opening may have a cross section area of e.g. 10 % or less of the cross section area of the respective synthesis channel 3.

[0068] Figure 2 shows a radial flow reactor 1 according to a second embodiment. The radial flow reactor 1 comprises a plurality of stacked radial flow reactor segments 15. The different radial flow reactor segments 15 are slightly rotated around the longitudinal axis L such that the different synthesis channels 3 of the radial flow reactor segments 15 are arranged at different positions in circumferential direction. This might improve heat removal by coolant.

[0069] Figure 3 shows a radial flow reactor 1 according to a third embodiment. The radial flow reactor 1 as shown in Figure 3 comprises a plurality of stacked radial flow reactor segments 15. The radial flow reactor segments 15 are not rotated with respect to each other as shown e.g. in Figure 2. Such a rotation would of course also be conceivable. Stacking a plurality of these radial flow reactor segments 15 axially next to each other is one option to increase the product output 11 of the radial flow reactor 1 . Another option would be to arrange the plurality of synthesis channels 3 at different axial positions along a relative long inflow channel 2, which comprises the respective openings. Figure 3 further indicates by dashed lines an outflow channel 4 arranged around the inflow channel 2 and around the synthesis channels 3. The plurality of synthesis channels 3 extend between the inflow channel 2 and the outflow channel 4. The outflow channel 4 comprises according to this embodiment an inner wall comprising openings, which fluidically connect the synthesis channels 3 with the outflow channel 4. Further, the outflow channel comprises an outer wall, which limits the extension of the outflow channel 4 in radial direction. The outflow channel 4 is configured to collect the product 1 1 from the plurality of synthesis channels 3 and to guide the product 1 1 out of the radial flow reactor 1 . Figure 3 further advantageously shows an intermediate space 6, which is arranged between the inflow channel 2 and the outflow channel 4. The intermediate space 6 is bridged by the synthesis channels 3. The intermediate space 6 is in particular configured to enable a coolant 61 to flow through the intermediate space 6 thereby cooling the synthesis channels 3, in particular the structured fixed-bed catalyst 31 during the operation of the radial flow reactor 1 .

[0070] Figure 4 shows a first longitudinal section through the radial flow reactor 1 according to a first embodiment. The radial flow reactor 1 as shown in Figure 4 mainly corresponds to the radial flow reactor 1 as shown in Figure 1. The radial flow reactor 1 comprises a centrally arranged inflow channel 2, a plurality of synthesis channels 3, which extend radially from the inflow channel 2. The synthesis channels 3 house the structured fixed- bed catalyst 32 and the pressure setting element 5. Further, the radial flow reactor 1 comprises an outflow channel 4, which surrounds the inflow channel 2 and the synthesis channels 3. The outflow channel 4 extends in longitudinal direction L, collects the synthesis product 1 1 and guides the product 11 out of the radial flow reactor 1. Further, Figure 4 shows the intermediate space 6 arranged between the inflow channel 2 and the outflow channel 4. The intermediate space 6 is configured to enable a coolant, e.g. air, oil, water or a respective coolant mixture, to stream around the synthesis channels 3 for cooling of the synthesis channels 3, in particular of the structured fixed-bed catalyst 31 . The radial flow reactor 1 as shown in Figure 4 may form the radial flow reactor segment 15, which may be stacked axially with additional radial flow reactor segments 15, as e.g. shown in Figure 2 or 3.

[0071] Figure 5 shows a second longitudinal section through the radial flow reactor 1 according to a second embodiment. This embodiment mainly corresponds to the embodiment as shown in Figure 4. The embodiment of Figure 5 shows that the synthesis channels 3 extends radially and axially with respect to the longitudinal axis L. In other words, the synthesis channels 3 are arranged inclined with respect to the longitudinal axis L. It is thereby possible to further increase the packaging density of the synthesis channels 3 and in particular of the structured fixed bed catalysts 31 . Further, the radial flow reactor 1 comprises two radial flow reactor segments 15, which are stacked onto one another. Further, the outflow direction of the product 11 along the outflow channel 4 is different compared to the embodiment of Figure 4.

[0072] Figure 6 shows a third longitudinal section through the radial flow reactor 1 according to a third embodiment. This embodiment shows the radial flow reactor 1 , wherein the different synthesis channels 3 are arranged at different axial positions with respect to the longitudinal axis L, also in circumferential direction. In other words, the openings in the inflow channel 2 and the synthesis channels 3 as well are e.g. arranged on a virtual helix, which extends along the inflow channel 2. Other arrangements are also conceivable. Figure 6 should in particular indicate that different axial positions of the synthesis channels 3 and / or different positions in circumferential direction are conceivable. Further, Figure 6 shows that the inflow channel 2 comprises a relatively long tube with the respective openings for the synthesis channels 3. Further, also the outflow channel 4 might comprise an inner tube and an outer tube arranged coaxially with respect to each other and in particular also coaxially with respect to the inflow channel 2. The inner wall of the outflow channel 4 comprises openings for the synthesis channel 3, such that the synthesis channels are fluidically connected to the inflow channel 2 and the outflow channel 4.

[0073] The Figures 7a, 7b und 7c shows three cross sections through the radial flow reactor 1 , in particular a radial flow reactor segment 15, showing different arrangement embodiments of the synthesis channels 3. All three embodiments show a centrally arranged inflow channel 2 and surrounding synthesis channels 3. The embodiment of Figure 7a shows three synthesis channels 3 arranged uniformly distributed in circumferential direction. It is visible that the intermediate space 6 takes up a relative large proportion of the available cross section area. The inflow channel 2 may have a triangular cylindrical shape. Figure 7b shows the radial flow segment 15 comprising four synthesis channels 3, the inflow channel 2 has a squared cylindrical shape and the proportion of the intermediate space 6 with respect to the synthesis channels 3 is smaller compared to the embodiment of Figure 7a. It is further visible that the outer dimension of the radial flow reactor segment 15 is larger compared to the embodiment of Figure 7a. This is the case because positioning four synthesis channels 3 with the same synthesis channels dimensions requires more space. Figure 7c shows the radial flow segment 15 comprising eight synthesis channels 3, the inflow channel 3 has a polygonal, in particular octagonal cylindrical shape and the portion of the intermediate space 6 is further reduced. Also here the outer dimension of the radial flow reactor segment 15 is larger compared to the other two embodiments. The packaging density of synthesis channels 3 with respect to the outer dimensions of the radial flow reactor 1 is the highest as shown in Figure 7c. It is possible to determine an optimum of the number of synthesis channels 3 with respect to the packaging density and the outer dimensions of the radial flow reactor 1 as will be explained in more detail with respect to Figure 17.

[0074] Figure 8 shows another embodiment of the radial flow reactor 1. Figure 8 in particular shows a radial flow reactor assembly 12 comprising a plurality of radial flow reactors 1. The plurality of radial flow reactors 1 extend parallel with respect to each other and share the same outflow channel 4. Figure 8 further shows three inflow channels 2 along which the reactants 10 stream into the respective radial flow reactor 1. The three radial flow reactors 1 are structured based on a plurality of radial flow reactor segments 15, which are stacked axially next to each other. Figure 8 further advantageously shows the intermediate space 6 and the coolant 61 streaming along the different intermediate spaces 6 for cooling of the synthesis channels 3 during operation of the radial flow reactor assembly 12. Figure 9 and Figure 10 show two different possible embodiments of the radial flow reactor assemblies 12 comprising a plurality of radial flow reactors 1. Both embodiments are shown in a cross sectional schematic view. The embodiment according to Figure 9 shows a circular cylindrical shape of the radial flow reactor assembly 12, comprising three radial flow reactors 1 . Each of the radial flow reactors 1 comprises in flow channel 2 and a plurality of synthesis channels 3. The radial flow reactor assembly 12 further comprises a shared outflow channel 4. The plurality of synthesis channels 3 of the three radial flow reactors 1 extend until reaching the outflow channel 4. The outflow channel 4 is restricted by an outer reactor wall 13 and by three inner walls, which surround the three radial flow reactors 1. The embodiment of Figure 10 differs from the embodiment of Figure 9 in the number of radial flow reactors 1 and the outer shape of the radial flow reactor assembly 12. Other embodiments and other numbers of radial flow reactors are of course also conceivable.

[0075] Figure 11 shows a container 14, in particular a standard shipment container comprising the radial flow reactor assembly 12 in a perspective view. The radial flow reactor assembly 12 is arranged at least partially in the container 14, which advantageously improves transportation of the radial flow reactor assembly 12. Connections e.g. for to the respective inflow channels 2, the outflow channels 4 etc. may be installed on site after positioning the respective container 14. The radial flow reactor assembly 12 according to this embodiment corresponds to the embodiment as shown in Figure 9 and comprises three radial flow reactors 1 arranged in parallel. Other embodiments e.g. the embodiment of Figure 10 are of course also conceivable.

[0076] Figure 12 shows a detailed a cross section through a synthesis channel 3 according to a first embodiment. Figure 13 shows a detailed longitudinal section through the synthesis channel 3 of Figure 12. The synthesis channel comprises the centrally arranged struc- tured fixed bed catalyst 31 , which comprises a catalyst body structure 32 defining a plurality of channels 33 within the structured fixed-bed catalyst 3, along which the reactants stream during operation of the radial flow reactor 1. The catalyst body structure 32 defines at least partially the reaction zone of the catalyst 2, in which the synthesis of methane takes place during operation of the reactor 1 . In this embodiment, the catalyst body structure 32 comprises a catalyst coating, which comprises the catalytically active materials. The catalyst body structure 32 provides the desired large surface and the coating provides the catalytically active materials. The catalyst body structure 32 of the structured fixed-bed catalyst 31 has a circular cylindrical shape (other shapes are also conceivable) and is surrounded on its shell surface by a catalyst body wall 34, which is for example made of sheet metal. The synthesis channel 3 as presented in the Figures 12 and 12 further comprises a channel shaped outer synthesis wall 35, which is for example a pipe or tube and in which the structured fixed-bed catalyst 2 and / or the pressure setting element 5 is positioned. The structured fixed-bed catalyst 31 and the synthesis wall 35 are preferably arranged coaxially with respect to each other, as best visible in the Figures 12 and 13. Figure 13 advantageously shows a synthesis channel longitudinal axis LS of the synthesis channel 3 along which the different parts of the reactor 1 extend. Figure 12 further advantageously indicates the coolant 61 streaming along the intermediate space 6 around the synthesis channel 3 for cooling.

[0077] The reactor 1 according to this variation further comprises a contact body 36, which is arranged between the structured fixed-bed catalyst 31 , in particular between the catalyst body wall 34, and the synthesis wall 35. The contact body 36 is configured to contact both parts for transferring heat from the structured fixed-bed catalyst 31 to the synthesis wall 35 during operation of the reactor 1. The contact body 36 preferably completely surrounds the structured fixed-bed catalyst 31 as best visible in Figure 12. The contact body 36 is preferably made of a corrugated sheet metal and contacts with first contact portions the catalyst body wall 34 and with second contact portions the synthesis wall 35. The contact body 36 further may comprise a contact body coating, which comprises catalytically active materials such that a bypass flow of reactants streaming along a gas gap between the catalyst body wall 34 and the synthesis wall 35 during operation of the reactor 1 also contact the contact body coating, thus catalyzing the chemical transformation of the reactants to methane. The contact body 36 is preferably fixedly arranged within the synthesis channel 3 by an adhesive joint, for example a soldering seam or a welding seam, which extends axially or in circumferential direction (or in both directions, like a helix) between the contact body 36 and / or the respective walls. The adhesive joint further advantageously increases the heat transfer between the different parts. The adhesive joint further may be configured to position the structured fixed bed catalyst 31 within the synthesis channel 3.

[0078] The Figures 12 and 13 further indicate schematically catalyst channels 33, which are defined by the catalyst body structure 32. The catalyst channels 33, have for example a circular, an angular, a rectangular, a squared or a honeycomb shape. The catalyst body structure 32 comprises for example 250 to 500 channels, which is for example made of ceramic or metal.

[0079] The Figures 12 and 13 further advantageously show a thermal bridge element 37 arranged within the structured fixed-bed catalyst 31. The thermal bridge element 37 has according to this embodiment a rod like shape or a circular cylindrical shape and is arranged concentrically with respect to the structured fixed-bed catalyst 31. The thermal bridge element 37 is thermally conductively connected to the structured fixed-bed catalyst 31 and extends throughout the structured fixed-bed catalyst 31 , in particular from an inlet end to an outlet end of the structured fixed-bed catalyst 31 . It is also conceivably that a plurality of structured fixed bed catalyst 31 are arranged in series within the synthesis channels 3. Figure 14a and Figure 14b show each a perspective view of the contact body 36 as used in the embodiment according to Figure 12 and 13. The contact body 36 extends in axial direction along the longitudinal axis LS and is for example made of a corrugated sheet metal such that the desired wave-like cross section of the contact body 36 is realized. The contact body 36 preferably comprises a contact body coating, which comprises the catalytically active materials. Figure 14b shows in a perspective view another embodiment of the contact body 36 having a star like cross section.

[0080] Figure 15 shows a plurality of possible embodiments of the pressure setting element 5. The pressure setting element 5 may comprise a wire screen material 51 or a perforated plate 52, in particular a sintered perforated metal plate. The pressure setting element 5 is configured to provide the functionality of a throttle when a fluid, in particular a gaseous fluid (=the reactants) stream through the pressure setting element 5 during the operation of the radial flow reactor 1 . The pressure setting element 5 as shown in Figure 15 may has dimensions, which correspond to the inner dimensions of the synthesis wall 35, such that the pressure setting element 5 is advantageously positionable within the synthesis channel 3 upstream of the structured fixed bed catalyst 31 .

[0081] Figure 16 shows a first diagram 100 showing of a plurality of radial velocity profiles for a radial flow reactor. The normed radial velocity vris plotted along the normed axial length z of the structured fixed-bed catalyst 31 . The dotted line a) shows an ideal velocity profile with no pressure drop. The first dashed line b) shows a radial velocity profile in which the radial pressure loss corresponds to the axial pressure loss and the inflow surface A in corresponds to the outflow surface A out. The second dashed line c) shows a radial velocity profile in which the radial pressure loss corresponds to the axial pressure loss, and the inflow surface A in is the half of the outflow surface (A in = 0.5*A_out). The line d) shows a radial velocity profile in which the radial pressure loss is four times the axial pressure loss and the the inflow surface A in is the half of the outflow surface (A in = 0.5*A_out). Figure 16 shows that by increasing the radial pressure loss, the velocity distribution in the reactor becomes better, even if channel cross-sectional areas differ.

[0082] Figure 17 shows a second diagram 110 showing a plurality of packaging density profiles for a radial flow reactor segment 15. The packaging density pd of different embodiments is plotted over the number n of structured fixed-bed catalysts 31 per segment 15. The first continuous line corresponds to an embodiment in which the ratio of the length of the structured fixed-bed catalysts 31 and the diameter of the structured fixed-bed catalysts 31 is 1 (L / d =1 ). In this case the optimal packaging density is reachable if ca. 3-4 of the structured fixed-bed catalysts 31 are use per segment 15. The first dashed line corresponds to an embodiment in which the ratio of the length of the structured fixed-bed catalysts 31 and the diameter of the structured fixed-bed catalysts 31 is 2 (L / d =2). In this case the optimal packaging density is reachable if ca. 8-10 of the structured fixed- bed catalysts 31 are use per segment 15. The second dashed line corresponds to an embodiment in which the ratio of the length of the structured fixed-bed catalysts 31 and the diameter of the structured fixed-bed catalysts 31 is 3 (L / d =3). In this case the optimal packaging density is reachable if ca. 14-20 of the structured fixed-bed catalysts 31 are used per segment 15.

[0083] Figure 18 shows a third diagram 120, in which an outer segment diameter is plotted over various structured packing tilt angles depending on the number of structured fixed-bed catalysts 31 per segment 15. The first continuous line shows the outer diameter with no tilt angle = 0°. The first dashed line shows the outer diameter of the segment 15 at a tilt angle of 45° = 45°. And the second dashed line shows the outer diameter of the segment 15 at a tilt angle of 60° = 60°. The tilt angle is the angle between the longitudinal axis LS of the synthesis channel 3 and a virtual plane through which is arranged perpendicular with respect to the longitudinal axis L of the radial flow reactor 1 . In the embodiments shown in Figures 17 and 18, the dimensions of the synthesis channels 3 mainly corresponds to the dimensions of the structured fixed-bed catalysts 31 .

[0084] Figure 19 shows a flow diagram schematically indicating the two method steps of operating a radial flow reactor 1 as described above and hereinafter. The diagram shows a first method step S1 and a second method step S2. In the first method step providing S1 a radial flow reactor 1 as described above and hereinafter, a radial flow reactor assembly 12 as described above and hereinafter or a container 14 as described above and hereinafter is provided S1 . In the second method step S2 the at least one radial flow reactor 1 is operated S2 by inducing into the radial flow reactor 1 in particular in the inflow chan- nel 2, the reactants 10.

[0085] LIST OF DESIGNATIONS

[0086] 1 radial flow reactor 20 41 dimensions of the outflow chan¬

[0087] 10 reactants nel

[0088] 11 product 5 pressure setting element 12 radial flow reactor assembly 51 wire screen material

[0089] 13 outer reactor wall 52 perforated plate

[0090] 14 container 25 6 intermediate space

[0091] 15 radial flow reactor segment 61 coolant

[0092] 2 inflow channel 21 dimensions of the inflow channel 100 first diagram

[0093] 3 synthesis channel 110 second diagram

[0094] 31 structured fixed-bed catalyst 30 120 third diagram

[0095] 32 catalyst body structure L longitudinal axis

[0096] 33 catalyst channels LS longitudinal axis of the synthesis 34 catalyst body wall channel

[0097] 35 synthesis wall S1 Providing

[0098] 36 contact body 35 S2 Operating

[0099] 37 thermal bridge element

[0100] 4 outflow channel

Claims

PATENT CLAIMS1 . Radial flow reactor (1 ), in particular for synthesis of methane and / or methanol, the radial flow reactor (1 ) extending along a longitudinal axis (L) and comprising: a. an inflow channel (2) extending along the longitudinal axis (L) and being configured to enable reactants (10) to stream into the radial flow reactor (1 ); b. a plurality of synthesis channels (3) extending radially with respect the longitudinal axis (L) starting at the inflow channel (2), thereby fluidically connecting the inflow channel (2) with the respective synthesis channel (3), the plurality of synthesis channels (3) comprising a structured fixed- bed catalyst (31 ); and c. a pressure-setting element (5) configured to set the pressure of the reactants (10) through the plurality of synthesis channels (3) during operation of the radial flow reactor (1 ).

2. The radial flow reactor (1 ) according to claim 1 , wherein the pressure setting element (5) is arranged in the flow path of the reactants (10) upstream of the structured fixed-bed catalysts (31 ), in particular within the respective synthesis channels (3), and / or wherein the pressure setting element (5) is arranged in the flow path of the products (11 ) downstream of the structured fixed-bed catalysts (31 ), in particular within the respective synthesis channels (3).

3. The radial flow reactor (1 ) according to any one of the preceding claims, wherein the pressure setting element (5) is selected for at least one of the plurality of synthesis channels (3) such that a uniform pressure drop through the plurality of the synthesis channels (3) arranged along the longitudinal axis (L) is provided.

4. The radial flow reactor (1 ) according to any one of the preceding claims, wherein the pressure setting element (5) comprises at least one of: a wire screen material (51 ), a perforated plate or a sintered metal plate (52).

5. The radial flow reactor (1 ) according any one of the preceding claims, further comprising an outflow channel (4) extending along the longitudinal axis (L) and being arranged at least partially around or within the inflow channel (2) with a predetermined distance to the inflow channel (2), thereby forming an intermediate space (6) between the inflow channel (2) and the outflow channel (4), the intermediate space (6) being bridged by the plurality or synthesis channels (3), wherein the outflow channel (4) is configured to collect the synthesis product (11 ) and to enable the synthesis product (11 ) to stream out of the radial flow reactor (1 ) in particular in longitudinal direction (L).

6. The radial flow reactor (1 ) according to claim 3, wherein the intermediate space (6) is configured to enable a coolant (61 ) to stream along the intermediate space (6) and around the plurality of synthesis channels (3) for cooling of the structured fixed-bed catalyst (31 ) arranged in each of the plurality of synthesis channels (3).

7. The radial flow reactor (1 ) according to any one of the preceding claims, wherein the plurality of synthesis channels (3) is arranged at the same axial position withrespect to the longitudinal axis (L), preferably uniformly distributed in circumferential direction, thereby forming at least virtually a radial flow reactor segment (15) comprising the plurality of synthesis channels (3).

8. The radial flow reactor (1 ) according to claim 7, wherein the quantity of synthesis channels (3) per radial flow reactor segment (15) is selected based on at least one of: the minimum required radial dimension of the structured fixed-bed catalyst (32), a ratio between length of the structured fixed-bed catalyst (33) and radial dimension of the structured fixed-bed catalyst (32), the minimum required axial dimension (35) of the synthesis channel (3), a minimum required coolant flow surface (34) per radial flow reactor segment (34), at least one radial dimension of the inflow channel (21 ), or the dimensions of the outflow channel (4).

9. The radial flow reactor (1 ) according to any one of the claims 7 to 8, wherein the quantity of synthesis channels (3) per radial flow reactor segment (36) is in a range from 5 to 25, preferably in a range from 8 to 20, more preferably in a range from 10 to 18, in case the ratio between the length of the structured fixed-bed catalyst (31 ) to the radial dimension of the structured fixed-bed catalyst (31 ) is in a range from 2 to 3.

10. The radial flow reactor (1 ) according to any one of the preceding claims, wherein for at least one, preferably all, of the plurality of synthesis channels (3) is inclined with respect to the radial direction.1 1 . The radial flow reactor (1 ) according to any one of the preceding claims, wherein the inflow channel (2), the synthesis channel (3) and / or the outflow channel (4) have at least partially an elliptical cylindrical shape, a circular cylindrical shape, a rectangular cylindrical shape or a polygonal cylindrical shape.

12. A radial flow reactor assembly (12) comprising a plurality of radial flow reactors (1 ) according to any one of the preceding claims, wherein at least two of the plurality of radial flow reactors (1 ) are arranged such that their respective longitudinal axis (L) are arranged parallel with respect to each other.

13. The radial flow reactor assembly (12) according to claim 12, wherein the plurality of radial flow reactors (1 ) are at least partially surrounded by an outer reactor wall (13), which preferably has a rectangular cylindrical shape or a circular cylindrical shape.

14. A container (14) comprising at least one of the radial flow reactor (1 ) according to one of the preceding claims 1 to 1 1 and / or comprising at least one radial flow reactor assembly (12) according to one of the claims 12 or 13.

15. A method of operating a radial flow reactor (1 ) for synthesis in particular of methane and / or methanol in an exothermic reaction, the method comprising the steps of: a. providing (S1 ) a radial flow reactor (1 ) according to one of the preceding claims 1 to 1 1 , a radial flow reactor assembly (12) according to one of the preceding claims 12 to 13 or a container (14) according to claim 14; b. operating (S2) the at least one radial flow reactor (1 ) by inducing into the radial flow reactor (1 ) in particular in the inflow channel (2), the reactants (10).

Images