Systems and methods for catalytic chemical reactions

Abstract

A catalytic reactor includes a vessel having at least one vessel inlet and at least one vessel outlet; a first reaction conduit positioned within the vessel and having a first reaction conduit inlet, a first reaction conduit interior surface, a first internal reaction volume, and a first reaction conduit exterior surface, wherein a catalytic material is positionable within the first reaction conduit; and a first electric resistance heater at least partially positioned within the first reaction conduit, wherein the first electric resistance heater is physically separated from the first internal reaction volume.

Description

SYSTEMS AND METHODS FOR CATALYTIC CHEMICAL REACTIONSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Application 63 / 649,598, titled “SYSTEMS AND METHODS FOR CATALYTIC CHEMICAL REACTIONS”, filed May 20, 2024, the contents of which are incorporated by reference herein.TECHNICAL FIELD

[0002] The subject matter disclosed herein relates broadly to the fields of chemical production and energy conversion, and more particularly to catalytic chemical reactors and reactions.BACKGROUND

[0003] Endothermic chemical reactions, such as the reverse-water gas shift reaction and the steam methane reforming reactions, can be used for producing valuable syngas, which can be used to form various alcohols and syncrude derived products in downstream processing units. The reverse-water gas shift (RWGS) reaction is an endothermic reaction producing syngas from carbon dioxide and hydrogen. The steam methane reforming reaction (SMR) is capable of producing hydrogen and carbon monoxide by a catalytic reaction of hydrocarbons with water. Natural gas is a typical hydrocarbon utilized for the steam methane reforming reaction. As these reactions are endothermic, reactants are typically heated to high temperatures to perform the reaction. Accordingly, conventional reactors subjected to carbon monoxide and hydrogen can suffer from the highly corrosive environment and metal dusting, a type of corrosive degradation of the reactor’s material. Further, these high operating temperatures have conventionally required expensive reactor materials, inefficient heating units, and frequent service intervals due to metal fatigue. There is a need for systems and methods for efficient chemical production, while reducing required material costs and / or service intervals for chemical reactor systems.SUMMARY

[0004] According to one aspect, a catalytic reactor includes a vessel having at least one vessel inlet and at least one vessel outlet; a first reaction conduit positioned within the vessel and having a first reaction conduit inlet, a first reaction conduit interior surface, a first internal reaction volume, and a first reaction conduit exterior surface, wherein a catalytic material is positionable within the first reaction conduit; and a first electric resistance heater at least partially positioned within the first reaction conduit, wherein the first electric resistance heater is physically separated from the first internal reaction volume.

[0005] According to another aspect, a catalytic reactor includes a vessel having at least one vessel inlet and at least one vessel outlet; a first reaction conduit positioned within the vessel and having a first reaction conduit inlet, a first reaction conduit interior surface, a first internal reaction volume, and a first reaction conduit exterior surface, wherein a catalytic material is positionable within the first reaction conduit; a first tubular structure coaxially arranged with the first reaction conduit and at least partially positioned within the first reaction conduit; a first helical fin structure positioned between the first reaction conduit interior surface and the first tubular structure; and a first electric heater element at least partially positioned within the first tubular structure.

[0006] According to another aspect, a method of performing a catalytic reaction includes utilizing a catalytic reactor, including: a vessel having at least one vessel inlet and at least one vessel outlet; a first reaction conduit positioned within the vessel and having a first reaction conduit inlet, a first reaction conduit interior surface, a first internal reaction volume, and a first reaction conduit exterior surface, wherein a catalytic material is positionable within the first reaction conduit; and a first electric resistance heater at least partially positioned within the first reaction conduit, wherein the first electric resistance heater is physically separated from the first internal reaction volume; introducing one or more reactants to the vessel through the at least one vessel inlet; providing electricity to the first electric resistance heater; introducing the one or more reactants to the first internal reaction volume; and transferring heat from the first electric resistance heater to the one or more reactants and contacting the one or more reactants with the catalytic material sufficient to form one or more products.BRIEF DESCRIPTION OF DRAWINGS

[0007] This written disclosure describes illustrative embodiments that are non-limiting and non-exhaustive. Reference is made to illustrative embodiments that are depicted in the figures, in which:

[0008] FIG. 1A illustrates catalytic reactor 100, according to some embodiments.

[0009] FIG. IB illustrates catalytic reactor 100, according to some embodiments.

[0010] FIG. 2A illustrates a portion of catalytic reactor 100, according to some embodiments.

[0011] FIG. 2B illustrates a side view of a portion of catalytic reactor 100, according to some embodiments.

[0012] FIG. 2C illustrates a section view of a portion of a first reaction conduit, according to some embodiments.

[0013] FIG. 2D illustrates a section view of a portion of the first reaction conduit, according to some embodiments.

[0014] FIG. 2E illustrates an end view of the first reaction conduit, according to some embodiments.

[0015] FIG. 2F illustrates a portion of catalytic reactor 100, according to some embodiments.

[0016] FIG. 3 illustrates catalytic reactor 300, according to some embodiments.

[0017] FIG. 4 illustrates method 400 for performing a catalytic reaction, according to some embodiments.

[0018] FIG. 5 illustrates system 500 including a catalytic reactor, according to some embodiments.DETAILED DESCRIPTIONDefinitions

[0019] As used herein, the terms “catalyst”, “catalytic material”, or the like refer to material which enables a chemical reaction to proceed at a faster rate or under different conditions (e.g., at a lower temperature) than otherwise possible. The catalysts of the presentinvention may include mixtures of one or more catalytic material(s) with other inert materials. The catalytic materials used in the present invention may be formed into desired shapes or sizes.

[0020] As used herein, the terms “fluid” or “fluids” refer to a liquid, a supercritical fluid, a gas, and / or a slurry.Discussion

[0021] Embodiments of the present disclosure provide systems and methods for catalytic chemical reactions. For example, systems and methods of the present disclosure can be used for endothermic reactions. These endothermic reactions can be used to produce precursors for use in the manufacture of hydrocarbons. For example, the present embodiments can be used to produce precursors for sustainable aviation fuel (SAF), waxes, alcohols, and the like. Examples of endothermic reactions include the reverse- water gas shift reaction and the steam methane reforming reaction. As discussed, the reverse-water gas shift reaction (RWGS) is an endothermic reaction producing carbon monoxide and water from carbon dioxide and hydrogen. The RWGS reaction is shown in Equation 1.CO2 + H2 CO + H2O (Equation 1)The steam methane reforming reaction (SMR) is capable of producing hydrogen and carbon monoxide by a reaction of hydrocarbons with water. Natural gas is a typical hydrocarbon utilized for the steam methane reforming reaction. The SMR reaction is shown in Equation 2.CH4+ H2O CO + 3H2(Equation 2)The dry methane reforming (DMR) reaction is an endothermic reaction and produces carbon monoxide and hydrogen. The dry methane reforming reaction is shown in Equation 3.CO2 + CEE 2CO + 2H2(Equation 3)As these reactions are endothermic, reactants are typically heated to high temperatures in catalytic reactors to perform the reactions. Importantly, catalytic reactors of the present disclosure provide efficient heating for endothermic reactions (e.g., RWGS, SMR, and / or DMR) while extending the service life of equipment.

[0022] FIG. 1A illustrates catalytic reactor 100, according to some embodiments. Catalytic reactor 100 includes vessel 110, first vessel inlet 112, second vessel inlet 114, exterior vessel surface 116, interior vessel surface 118, reactant flow path 119, first reaction conduit 120, firstheating element 122, first tubular structure 124, reactor tube sheet 180, vessel outlet 190, proximal end 193 of vessel 110, and distal end 195 of vessel 110. First reaction conduit 120 includes first reaction conduit inlet 130, first reaction conduit interior surface 132, first reaction conduit exterior surface 134, first internal reaction volume 136, and first reaction conduit outlet 182. Catalytic material 121 is positionable within at least a portion of catalytic reactor 100, such as positionable within at least a portion of first reaction conduit 120.

[0023] Vessel 110 is shown as at least partially translucent in FIG. 1A to better illustrate the internal structure of catalytic reactor 100. Vessel 110, which also may be referred to as an encasement, may be tubular in shape with internal walls. While vessel 110 is generally tubular in shape, in other embodiments, vessel 110 may take other shapes sufficient for catalytic chemical reactions of the present disclosure. Vessel 110 can extend from proximal end 193 to distal end 195. As shown, first reaction conduit 120 and reactor tubesheet 180 may be positioned within vessel 110. First reaction conduit 120 is at least partially positioned within vessel 110. Vessel 110 can be in the form of a pressure vessel. Vessel 110 may be formed from various materials, such as various metals, metal alloys, and / or ceramics. In one example, vessel 110 is formed using at least stainless steel, optionally coated with a corrosion-resistant layer. Vessel 110 can include internal insulation, such as an alumina or alumina-silicate. For example, non-porous plates can be used for insulation.

[0024] Catalytic reactor 100 may include one or more inlets for reactants or other fluids. As shown, catalytic reactor 100 includes first vessel inlet 112 and second vessel inlet 114. While two vessel inlets are illustrated, in other embodiments, catalytic reactor 100 may include only one inlet, or catalytic reactor 100 may include more than two inlets. First vessel inlet 112 and second vessel inlet 114 are sufficient to receive one or more reactants, such as at least one of carbon dioxide, hydrogen, water, and methane. For example, if performing the RWGS reaction, first vessel inlet 112 and / or second vessel inlet 114 can receive hydrogen gas and carbon dioxide gas. If performing the SMR, first vessel inlet 112 and / or second vessel inlet 114 can receive methane and water vapor. First vessel inlet 112 and second vessel inlet 114 can each define a channel for transferring the one or more reactants into vessel 110. In one example, multiple inlets can be utilized to ensure substantially uniform flow distribution in larger vessels.

[0025] With regard to the fluidic flow path of one or more reactants in catalytic reactor 100, during use, one or more reactants are directed through first vessel inlet 112 and / or second vessel inlet 114 and can initially be directed in a direction at least substantially perpendicular to at least one of first reaction conduit 120. As such, the one or more reactants can contact exterior surface(s), such as first reaction conduit exterior surface 134, of first reaction conduit 120 sufficient to transfer heat from the exterior surfaces to the one or more reactants. Importantly, transferring heat to the one or more reactants can also reduce the operating temperature of one or more portions of first reaction conduit 120. For example, the flow rate of one or more reactants entering vessel 110 can be adjusted to maintain materials within vessel 110 below the metal creep temperature. By using the one or more reactants as a coolant for the reaction conduits, the maximum mean metal temperature is kept below the metal creep temperature, extending service life.

[0026] After entering vessel 110, the one or more reactants can be directed in a substantially distal direction toward distal end 195 of vessel 110 (example flow path(s) are shown in FIG. IB). During operation, the one or more reactants enter first reaction conduit 120 near distal end 195 of vessel 110. The first reaction conduit inlet 130 is positioned within vessel 110 and is in fluid communication with one or more of first vessel inlet 112 and second vessel inlet 114. The one or more reactants enter first reaction conduit 120 at first reaction conduit inlet 130. In one example, the temperature of the one or more reactants entering first reaction conduit inlet 130 is greater than the temperature of the one or more reactants entering first vessel inlet 112. First reaction conduit inlet 130 is capable of receiving the one or more reactants and permits the transfer of the one or more reactants into first internal reaction volume 136.

[0027] First internal reaction volume 136 is a space or volume within first reaction conduit 120 where the one or more reactants can be contacted with one or more species of catalyst materials in order to promote or facilitate chemical conversion of the reactants to one or more reaction products. First internal reaction volume 136 can be at least partially defined by first reaction conduit interior surface 132 and first tubular structure 124. First internal reaction volume 136 can be in fluid communication with first reaction conduit inlet 130. First reaction conduit 120 is generally at least partially filled with one or more species of catalyst materials,such as catalytic material 121, positioned or arranged within at least a portion of first internal reaction volume 136.

[0028] Catalytic material 121 can occupy space in at least a portion of first internal reaction volume 136. Catalytic material 121 can include and / or be present on a catalyst support material. Catalytic material 121 can be suspended within first internal reaction volume 136 sufficient to substantially prevent catalytic material 121 from exiting first internal reaction volume 136 during operation. In one example, catalytic material 121 is not in contact with heating element 122. First tubular structure 124 can separate heating element 122 from at least one of catalytic material 121 and one or more fluids, such as reactant(s) and / or product(s) within first internal reaction volume 136.

[0029] Catalytic material 121 can include a suitable catalyst for a catalytic chemical reaction, such as an endothermic reaction. Catalytic material 121 can include one or more catalyst materials of the present disclosure. In one example, the catalytic material 121 can occupy over 50 vol% of first internal reaction volume 136 total volume. In another example, the catalytic material 121 can occupy over 60 vol% of first internal reaction volume 136 total volume. In another example, the catalytic material 121 can occupy over 70 vol% of first internal reaction volume 136 total volume.

[0030] The first heating element 122 can be utilized to convert electrical energy into thermal energy. First heating element 122 can include a first electric heater element for electrically converting electrical energy to thermal energy. In one example, first electric heater element can include one or more electric resistance heaters (e.g., first electric resistance heater). Electric resistance heaters utilize electricity flowing through a conductor (e.g., wire and / or coil) to generate heat, at least in part due to resistance. In one example, the electric resistance heater is an insertion / immersion type heater configured with both electrical leads on the same end of first heating element 122. Accordingly, other components of catalytic reactor 100 can be free to independently expand and / or contract, such as first reaction conduit 120. Many conventional reactors utilize gas fired burners as a source of heat, often on the outside of the reaction chamber. Unfortunately, designs using gas fired burners undergo many heat cycles. Each heat cycle shortens the lifespan of certain reactor components. While embodiments of the present disclosureinclude first electric heater elements, heat may be applied, additionally or alternatively, to at least a portion of catalytic reactor 100 using other forms of energy, such as burning a gas and / or fuel.

[0031] First heating element 122 is generally at least partially positioned within the first reaction conduit 120 but may extend proximally or distally beyond first reaction conduit 120. At least a portion of first heating element 122 can be physically separated (e.g., using a suitable separation structure) from at least one of catalytic material 121 and first internal reaction volume 136. Physical separation can prevent direct physical contact of first heating element 122 with at least one of catalytic material 121 and first internal reaction volume 136. Physical separation can prevent fluid communication between first heating element 122 with at least one of catalytic material 121 and first internal reaction volume 136. For example, physical separation can include preventing direct fluid contact between first heating element 122 and one or more reactant and / or product gases being processed in catalytic reactor 100. First tubular structure 124 can physically separate first heating element 122 from at least one of catalytic material 121 and first internal reaction volume 136. In one non-limiting example, first reaction conduit 120 does not carry any electrical current. This design can negate the need for isolating electrical tubesheets from vessel 110 and can reduce metal expansion failure issues. Further, electrical leads may not be required on both ends of vessel 110, such as proximal end 193 and distal end 195.

[0032] In one example, first heating element 122 and / or first tubular structure 124 is coaxially arranged with first reaction conduit 120. First heating element 122 may be utilized to supply heat to increase the temperature of fluids and / or materials within first reaction conduit 120. For example, first heating element 122 may be utilized to supply heat to one or more reactants within first internal reaction volume 136. In one non-limiting example, first heating element 122 indirectly heats the one or more reactants by transferring thermal energy to at least one of the first tubular structure 124 and first helical fin structure 126. During operation, a temperature gradient may be maintained in one or more portions of catalytic reactor 100, such as in first internal reaction volume 136. In one example, since first heating element 122 can be contained in a separate volume from first internal reaction volume 136, if catalytic material 121 is replaced after operation, first heating element 122 does not also have to be replaced or removed. In one non-limiting example, catalytic material 121 is not coated on, or in contact with, first heating element 122.

[0033] First tubular structure 124 can substantially surround first heating element 122, such as sufficient to enclose first heating element 122. First tubular structure 124 and / or vessel 110 can include one or more inlets for introducing electrical wiring / conduit to first heating element 122. In one example, the one or more inlets of first tubular structure 124 can be hermetically sealed. In another example, a gas volume is present between first tubular structure 124 and first heating element 122. For example, first tubular structure 124 can be pressurized with a fluid (e g., inert gas, such as argon gas) for substantially matching the pressure within first internal reaction volume 136 during operation. By substantially matching the pressure within first internal reaction volume 136 during operation, the pressure inside and outside first tubular structure 124 are substantially equalized for reducing material fatigue and improving equipment lifetime. In some embodiments, first tubular structure 124 can include one or more gas inlets for introducing gas within first tubular structure 124 to regulate the pressure within first tubular structure 124. A pump can be utilized to pressurize the volume within first tubular structure 124. First tubular structure 124 can be formed from various materials, such as a ceramic material. In one example, first tubular structure 124 is formed from silicon carbide and / or a fiber-reinforced silicon carbide. Various portions of catalytic reactor 100 can be formed using a ceramic and / or metal alloy.

[0034] A volume can be present between first tubular structure 124 and first heating element 122. Accordingly, a packing material configured to facilitate heat transfer can be placed within the volume between first tubular structure 124 and first heating element 122. By introducing a packing material configured to facilitate heat transfer into first tubular structure 124, a packing material configured to facilitate heat transfer having a higher thermal conductivity than a gas can improve the overall heat transfer from first heating element 122 to first tubular structure 124 and one or more reactants.

[0035] First reaction conduit outlet 182 can be in fluid communication with vessel outlet 190. First reaction conduit outlet 182 can include an opening / channel sufficient to at least allow one or more products to exit first reaction conduit 120. If operating a RWGS reaction, the one or more products can include at least one of carbon monoxide, water, and any unreacted species. If operating the SMR, the one or more products can include at least one of carbon monoxide, hydrogen and any unreacted species. As illustrated in FIG. 1A, first reaction conduit outlet 182is positioned adjacent or near the proximal end 193 of vessel 110, sufficient for the one or more products to transfer heat to one or more reactants entering vessel 110.

[0036] In one example, catalytic reactor 100 is a counter-flow reactor. A counter-flow reactor exhibits one or more reactants in at least a portion of the catalytic reactor 100 flowing in the substantially opposite direction to one or more products in at least a portion of the catalytic reactor 100 and / or one or more products exiting the catalytic reactor 100. In another example, one or more reactants used for catalytic reactor 100 enter, and one or more products produced by catalytic reactor 100 exit, on proximal end 193 of vessel 110. The counter-flow operation can enhance heat transfer and promote cooling of first reaction conduit 120 using one or more reactants.

[0037] Reactor tubesheet 180 is generally in contact with at least a portion of first reaction conduit 120. In other embodiments, other structures capable of supporting at least a portion of first reaction conduit 120 are used in place of a tubesheet. Reactor tubesheet 180 may be positioned adjacent to first reaction conduit outlet 182. Reactor tubesheet 180 is configured to secure one or more of the reaction conduits of the present disclosure within vessel 110. In one example, first reaction conduit 120 may only be in contact with reactor tubesheet 180 on one end (not constrained on both ends), sufficient to allow for axial expansion of first reaction conduit 120 during operation. This can reduce stresses and can increase the lifetime of the materials in vessel 110.

[0038] One or more products are transferred out of first reaction conduit outlet 182 and can be directed toward vessel outlet 190. Vessel outlet 190 can be in fluid communication with first reaction conduit outlet 182. Vessel outlet 190 can define a channel for transferring the one or more products out of vessel 110. While one outlet, vessel outlet 190, is illustrated in FIG. 1A, additional outlets may be utilized for transferring one or more products from inside vessel 110 to outside of vessel 110. Vessel outlet 190 may be in fluid communication with one or more downstream processing units, such as a downstream water knock-out unit.

[0039] Importantly, excess heat transferred from first heating element 122 to first internal reaction volume 136 can be absorbed through the first reaction conduit 120 wall and can be used to preheat the feed gas. This can eliminate the need for an isolated feed effluent exchanger that can require an internal refractory design of the exchanger and interconnecting pipe. The colderfeed gas on the outside of first reaction conduit 120 can result in a vessel 110 metal temperature that is below the creep temperature range. The feed gas can use the most efficient flow configuration for flow around first reaction conduit 120. For example, the flow of fluid(s) orthogonal to the reactor tube first reaction conduit 120, such as counter-flow, produces a heat transfer coefficient three times higher than axial flow.

[0040] FIG. IB illustrates catalytic reactor 100, according to some embodiments. Catalytic reactor 100 shown in FIB. IB includes one or more additional feature(s) and / or configurations that can be present in catalytic reactor 100. Catalytic reactor 100 includes at least one of: vessel 110, first vessel inlet 112, second vessel inlet 114, baffie(s) 115, exterior vessel surface 116, interior vessel surface 118, reactant flow path 119, first reaction conduit 120, second reaction conduit 150, third reaction conduit 160, fourth reaction conduit 170, reactor tubesheet 180, vessel outlet 190, proximal end 193, and distal end 195. Example reactant flow path 117 shows an example of the direction that one or more reactants can travel within vessel 110, and example product flow path 188 shows an example of the direction that one or more products can travel as exiting vessel 110.

[0041] Vessel 110 is shown as at least partially translucent in FIG. IB to better illustrate the internal structure of catalytic reactor 100. Vessel 110, which also may be referred to as an encasement, may be tubular in shape with internal walls. While vessel 110 is generally tubular in shape, in other embodiments, vessel 110 may take other shapes sufficient for catalytic chemical reactions of the present disclosure. Vessel 110 can extend from proximal end 193 to distal end 195. As shown, baffle(s) 115, first reaction conduit 120, second reaction conduit 150, third reaction conduit 160, fourth reaction conduit 170, and reactor tubesheet 180 may be positioned within vessel 110. Vessel 110 may be formed from various materials, such as various alloys and ceramics.

[0042] Catalytic reactor 100 may include one or more inlets for reactants or other fluids. As shown, catalytic reactor 100 includes first vessel inlet 1 12 and second vessel inlet 114. While two vessel inlets are illustrated, in other embodiments, catalytic reactor 100 may include only one inlet, or catalytic reactor 100 may include more than two inlets. First vessel inlet 112 and second vessel inlet 114 are sufficient to receive one or more reactants, such as at least one of carbon dioxide, hydrogen, water, and methane. For example, if performing the RWGS reaction,first vessel inlet 112 and / or second vessel inlet 114 can receive hydrogen gas and carbon dioxide gas. If performing the SMR, first vessel inlet 112 and / or second vessel inlet 114 can receive methane and water vapor. First vessel inlet 112 and second vessel inlet 114 can each define a channel for transferring the one or more reactants into vessel 110. In one example, multiple inlets can be utilized to ensure substantially uniform flow distribution in larger vessels.

[0043] With regard to the fluidic flow path of one or more reactants in catalytic reactor 100, during use one or more reactants are directed through first vessel inlet 112 and / or second vessel inlet 114 and can initially be directed in a direction at least substantially perpendicular to at least one of first reaction conduit 120, second reaction conduit 150, third reaction conduit 160, fourth reaction conduit 170. Accordingly, fluid (such as the one or more reactants) may be introduced into vessel 110 in a substantially perpendicular flow direction with respect to first axis of extension 138 (discussed further in FIG. IB). As such, the one or more reactants can contact exterior surfaces of first reaction conduit 120, second reaction conduit 150, third reaction conduit 160, and / or fourth reaction conduit 170 sufficient to transfer heat from the exterior surfaces to the one or more reactants. Importantly, transferring heat to the one or more reactants can also reduce the operating temperature of one or more portions of first reaction conduit 120, second reaction conduit 150, third reaction conduit 160, and / or fourth reaction conduit 170. For example, the flow rate of one or more reactants entering vessel 110 can be adjusted to maintain materials within vessel 110 below the metal creep temperature. By using the one or more reactants as a coolant for the reaction conduits, the maximum mean metal temperature is kept below the metal creep temperature, extending service life. In other embodiments, with regard to the fluidic flow path of one or more reactants in catalytic reactor 100, during use one or more reactants are directed through first vessel inlet 112 and / or second vessel inlet 114 and can initially be directed in a direction other than substantially perpendicular discussed herein, such as at least substantially parallel to at least one of first reaction conduit 120, second reaction conduit 150, third reaction conduit 160, and / or fourth reaction conduit 170.

[0044] After entering vessel 110, the one or more reactants can be directed in a substantially distal direction toward distal end 195 of vessel 110. The one or more reactants can travel along reactant flow path 119. An example path, example reactant flow path 117, is shown in FIG. IB. In one example, reactant flow path 119 is at least partially defined by interior vesselsurface 118 and first reaction conduit 120. In another example, reactant flow path 119 may be defined by the combination of one or more of baffie(s) 115, interior vessel surface 118, and exterior surfaces of first reaction conduit 120, second reaction conduit 150, third reaction conduit 160, fourth reaction conduit 170. Reactant flow path 119 can be in fluid communication with first vessel inlet 112 and / or second vessel inlet 114 and first reaction conduit inlet 130.

[0045] During operation, the one or more reactants may be directed to traverse around / along baffle(s) 115, interior vessel surface 118, and exterior surfaces of first reaction conduit 120, second reaction conduit 150, third reaction conduit 160, fourth reaction conduit 170. In one example, baffle 115 includes a plurality of baffles. In another example, baffle 115 includes at least one of a disc baffle and a donut baffle. Baffle 115 may include one or more cutouts for the one or more reactants to flow through. Baffle 115 can be positioned adjacent to an exterior surface of first reaction conduit 120, second reaction conduit 150, third reaction conduit 160, and / or fourth reaction conduit 170. In one example, baffle 115 is in contact with interior vessel surface 118. Baffles 115 present in vessel 110 can be in the form of an alternating configuration. For example, the alternating configuration can include one or more disc type baffles alternating with one or more donut type baffles, such as alternating along extension 138.

[0046] In one non-limiting example, the feed gas first contacts a donut type baffle 115 to promote flow symmetry. The flow of feed gas can move axially down first reaction conduit 120 until encountering a disc type baffle 115 sufficient to be redirected outward across first reaction conduit 120. Upon reaching interior vessel surface 118, the flow drops down axially around a gap between the disc type baffle 115 and interior vessel surface 118. This flow pattern can continue until reaching distal end 195 and entering first reaction conduit inlet 130. Catalytic reactor 100 may further include one or more of seal rods, strips, or dummy tubes to optimize the gas velocity in catalytic reactor 100.

[0047] During operation, the one or more reactants enter first reaction conduit 120 near distal end 195 of vessel 110. First reaction conduit 120 includes first heating element 122, first tubular structure 124, first helical fin structure 126, first reaction conduit inlet 130, first reaction conduit interior surface 132, first reaction conduit exterior surface 134, first internal reaction volume 136, and first reaction conduit outlet 182. The first reaction conduit inlet 130 is positioned within vessel 110 and is in fluid communication with one or more of first vessel inlet112 and second vessel inlet 114. The one or more reactants enter first reaction conduit 120 at first reaction conduit inlet 130. In one example, the temperature of the one or more reactants entering first reaction conduit inlet 130 is greater than the temperature of the one or more reactants entering first vessel inlet 112. First reaction conduit inlet 130 is capable of receiving the one or more reactants and permits the transfer of the one or more reactants into first internal reaction volume 136. FIG. IB also illustrates first axis of extension 138. First reaction conduit 120 generally extends along first axis of extension 138. Second reaction conduit 150, third reaction conduit 160, and fourth reaction conduit 170 can extend in a substantially parallel direction to first reaction conduit 120.

[0048] First internal reaction volume 136 is a space or volume within first reaction conduit 120 where the one or more reactants can be contacted with one or more species of catalyst materials in order to promote or facilitate chemical conversion of the reactants to one or more reaction products. First internal reaction volume 136 is defined by first reaction conduit interior surface 132, first tubular structure 124, and first helical fin structure 126. First internal reaction volume 136 is in fluid communication with first reaction conduit inlet 130. Although not shown, first reaction conduit 120 is generally at least partially filled with one or more species of catalyst materials positioned or arranged within first internal reaction volume 136. First reaction conduit 120 may include catalyst material having various forms or shapes, such as spherical particles or beads, and the catalyst may include a support.

[0049] In one example, the catalyst can occupy over 50 vol% of first internal reaction volume 136 total volume. In another example, the catalyst can occupy over 60 vol% of first internal reaction volume 136 total volume. In another example, the catalyst can occupy over 70 vol% of first internal reaction volume 136 total volume.

[0050] The catalyst may include the catalysts disclosed in PCT Application No. PCT / US24 / 25375, filed on April 19, 2024, the contents of which are incorporated by reference in its entirety. In one non-limiting example, the catalyst can include catalytically-active material including a formula: CeJQO, wherein Ce is Cerium, J includes at least one of Zirconium, Hafnium, Niobium, Tantalum, and Titanium, Q includes at least one of one or more metals and one or more metalloids, and O is oxygen. The one or more metals can be selected from Praseodymium, Terbium, Thulium, Europium, Samarium, Ytterbium, Gallium, Indium, Tin, andBismuth. These one or more metals can be redox active. The one or more metalloids can be selected from Germanium and Antimony. These one or more metalloids can be redox active. Accordingly, Q can include at least one of Praseodymium, Terbium, Thulium, Europium, Samarium, Ytterbium, Gallium, Germanium, Indium, Tin, Antimony, and Bismuth.

[0051] The catalyst may include the catalysts disclosed in PCT Application No. PCT / US23 / 23868, filed on May 30, 2023, the contents of which are incorporated by reference in its entirety. In some embodiments, the catalyst includes one or more “MAX or MAX-LIKE phase materials” which are defined herein as a material having the chemical formula shown below as Formula 1 :Mb+iAdJeXf (Formula 1) where M is a transition metal (e.g., scandium, yttrium, lutetium, titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, manganese, or iron); A is a Group A element (e.g., iridium, palladium, copper, gold, zinc, cadmium, aluminum, gallium, indium, thallium, silicon, germanium, tin, lead, phosphorous, arsenic, bismuth, or sulfur); J is a dopant; and X is either carbon or nitrogen. According to Formula 1, the MAX or MAX-LIKE phase material may include the following formula: Mb+iAXr, where b is either 1, 2, or 3 and f is either 1, 2, 3, or 4. In the preceding sentence, b and f may be equal. Other catalyst materials may be utilized, such as nickel-containing and / or copper-containing catalysts.

[0052] The support may be in the form of a support bead. For example, the support may include a substantially spherical support bead. The shape of the support bead may be shapes other than a sphere, such as a cylindrical shape or a ring. The catalyst may be in the form of porous beads, pellets, tubes, Raschig rings, Super Raschig rings, Pall rings, Bialecki rings, extrudates, lobes, saddles, and / or other shapes.

[0053] As discussed, first reaction conduit 120 includes first heating element 122. The first heating element 122 can be utilized to convert electrical energy into thermal energy. In one example, first heating element 122 is an electric resistance heater. The first heating element is generally positioned within the first reaction conduit 120 but may extend proximally or distally beyond first reaction conduit 120. In one example, first heating element 122 is coaxially arranged with first reaction conduit 120. First heating element 122 may be utilized to supply heat to increase the temperature of fluids and / or materials within first reaction conduit 120. Forexample, first heating element 122 may be utilized to supply heat to one or more reactants within first internal reaction volume 136. In one non-limiting example, first heating element 122 indirectly heats the one or more reactants by transferring thermal energy to at least one of the first tubular structure 124 and first helical fin structure 126. In another non-limiting example, the combination of first heating element 122, first tubular structure 124, and first helical fin structure 126 directly heats the one or more reactants. During operation, a temperature gradient may be maintained in one or more portions of catalytic reactor 100, such as in first internal reaction volume 136.

[0054] As discussed, first reaction conduit 120 includes first helical fin structure 126. First heating element 122 can provide heat to first helical fin structure 126. In one example, first helical fin structure 126 is positioned between first reaction conduit interior surface 132 and first heating element 122. In one example, first helical fin structure 126 is in contact with first tubular structure 124. First tubular structure 124 may be coaxially arranged with first reaction conduit 120. First tubular structure 124 can substantially surround first heating element 122. In another example, first helical fin structure 126 is not in contact with first reaction conduit interior surface 132 and may include a gap (discussed in FIG. 2A) of various distances between first helical fin structure 126 and first reaction conduit interior surface 132 (discussed further in FIG. 2A). In another example, first helical fin structure 126 can be in the form of a monolithic structure with first tubular structure 124. During operation, the one or more reactants traverse and rotate around first heating element 122 sufficient for conversion to one or more products via direct contact with the catalyst.

[0055] First helical fin structure 126 can include a single helix or spiral configuration. Alternatively, or additionally, first helical fin structure 126 may include a multi-helix fin structure, such as a double helix (e.g., see FIG. 2C) or triple helix or more configuration. In some embodiments, first helical fin structure 126 can include various helices along the length of first tubular structure 124. For example, a first portion of first helical fin structure 126 along a first portion of first tubular structure 124 can include a single helix, while a second portion of first helical fin structure 126 along a second portion of first tubular structure 124 can include a double helix or triple helix configuration. Accordingly, the heat exchange capacity can be tailored along the length of first tubular structure 124 (and among the various reaction tubes incatalytic reactor 100) so that the heat is managed to avoid metal creep issues, while at the same time providing the most efficient heat to the reaction. In one example, first tubular structure 124 can be formed as a single structure with first helical fin structure 126.

[0056] In one example, first helical fin structure 126 completely rotates (360°) around first tubular structure 124 such that the pitch ranges from about 10 cm to about 60 cm. In another example, first helical fin structure 126 completely rotates (360°) around first tubular structure 124 such that the pitch ranges from about 20 cm to about 50 cm. In yet another example, first helical fin structure 126 completely rotates (360°) around first tubular structure 124 such that the pitch ranges from about 25 cm to about 35 cm. For example, first helical fin structure 126 can completely rotate (360°) around first tubular structure 124 such that the pitch is about 30.48 cm.

[0057] In one example, first helical fin structure 126 can exhibit various pitch distances and fin angles for ease of catalyst loading. First helical fin structure 126 can exhibit a variable pitch along the length of first tubular structure 124. In another example, the specific pitch for first helical fin structure 126 is selected to increase the heat transfer coefficient. In one example, the temperature of first tubular structure 124 and first helical fin structure 126 can be uniform and tailored axially to substantially match the length of the catalyst bed and preheating length. In another example, at least a portion of first tubular structure 124 and first helical fin structure 126 may be unheated.

[0058] While first helical fin structure 126 is illustrated in FIG. IB as a double helix, alternatively, or additionally, embodiments of the present disclosure include utilizing non-helical fin structure(s). In one example, the non-helical fin structure is positioned between first reaction conduit interior surface 132 and first heating element 122. For example, the non-helical fin structure can include one or more similar configurations to first helical fin structure 126, such as not being in contact with first reaction conduit interior surface 132 and including a gap (discussed in FIG. 2A) of various distances between the non-helical fin structure and first reaction conduit interior surface 132 (discussed further in FIG. 2A). In one example, the non- helical fin structure is in contact with first tubular structure 124. Various types of fins can be utilized as non-helical fin structures. For example, the fin can include one or more axial fins. Axial fins can extend along an axial direction (e.g., extension 138) of the reaction conduit (e.g., first reaction conduit 120). Axial fins can include flat fins and / or corrugated fins.

[0059] First reaction conduit outlet 182 can be in fluid communication with vessel outlet 190. First reaction conduit outlet 182 can include an opening / channel sufficient to at least allow one or more products to exit first reaction conduit 120. If operating a RWGS reaction, the one or more products can include at least one of carbon monoxide, water, and any unreacted species. If operating the SMR, the one or more products can include at least one of carbon monoxide, hydrogen and any unreacted species. As illustrated in FIG. IB, first reaction conduit outlet 182 is positioned adjacent or near the proximal end 193 of vessel 110, sufficient for the one or more products to transfer heat to one or more reactants entering vessel 110. The diameter of first reaction conduit 120 may be less than about 15 cm. In one example, the diameter of first reaction conduit 120 is less than about 7.6 cm. In another example, the diameter of first reaction conduit 120 is less than about 10 cm. In one example, the diameter of first reaction conduit 120 is greater than about 5 cm.

[0060] As shown in FIG. IB, catalytic reactor 100 includes first reaction conduit 120, second reaction conduit 150, third reaction conduit 160, and fourth reaction conduit 170. Second reaction conduit 150, third reaction conduit 160, and fourth reaction conduit 170 may include the features, configurations, and / or materials of first reaction conduit 120. For example, second reaction conduit 150 may include a second reaction conduit inlet, a second reaction conduit interior surface, a second internal reaction volume, and a second reaction conduit exterior surface. A second electric resistance heater may be positioned within second reaction conduit 150. Second reaction conduit 150 may include a second helical fin structure, wherein the second helical fin structure is positioned between the second reaction conduit interior surface and the second electric resistance heater. Portions of second reaction conduit 150, third reaction conduit 160, and fourth reaction conduit 170 are not shown and / or labeled for clarity. Alternative to the illustration in FIG. IB, catalytic reactor 100 may include less than four reaction conduits or more than four reaction conduits.

[0061] Reactor tubesheet 180 is generally in contact with at least a portion of first reaction conduit 120. Reactor tubesheet 180 may be positioned adjacent to first reaction conduit outlet 182. Reactor tubesheet 180 can be in contact with one or more of first reaction conduit 120, second reaction conduit 150, third reaction conduit 160, and fourth reaction conduit 170. Reactor tubesheet 180 is configured to secure one or more of the reaction conduits of the presentdisclosure within vessel 110. In one example, first reaction conduit 120 may only be in contact with reactor tubesheet 180 on one end (not constrained on both ends), sufficient to allow for axial expansion of first reaction conduit 120 during operation. This can reduce stresses and can increase the lifetime of the materials in vessel 110.

[0062] One or more products are transferred out of first reaction conduit outlet 182 and can be directed toward vessel outlet 190. Vessel outlet 190 can be in fluid communication with first reaction conduit outlet 182. As an example, example product flow path 188 is shown to illustrate that one or more products can be directed out of vessel 110 toward proximal end 193 of vessel 110. Vessel outlet 190 can define a channel for transferring the one or more products out of vessel 110. While one outlet, vessel outlet 190, is illustrated in FIG. IB, additional outlets may be utilized for transferring one or more products from inside vessel 110 to outside of vessel 110. Vessel outlet 190 may be in fluid communication with one or more downstream processing units, such as a downstream water knock-out unit.

[0063] Catalytic reactor 100 may further include a jacketed syngas chamber and a heat recovery exchanger. The jacketed syngas chamber and heat recovery exchanger may be positioned within vessel 110 or in fluid communication with vessel 110. For example, the jacketed syngas chamber may be positioned adjacent to reactor tubesheet 180, and the heat recovery exchanger can be positioned near proximal end 193. The jacketed syngas chamber can be positioned between first reaction conduit 120 and the heat recovery exchanger. The jacketed syngas chamber and the heat recovery exchanger can collectively cool the one or more products prior to exiting vessel 110. Non-limiting examples, shown in FIG. 3, include a jacketed syngas chamber 314 and the heat recovery exchanger 380. For example, the jacketed syngas chamber 314 and the heat recovery exchanger 380 can utilize a coolant to capture energy from the one or more products. This also cools the metals of the jacketed syngas chamber 314 and the heat recovery exchanger 380 - allowing for the selection of stainless steels or lower alloys. Lower metal temperatures allow for much higher tensile strength and a thinner required thickness of metals.

[0064] The coolant may be utilized to internally cool one or more tubesheets in catalytic reactor 100. In one non-limiting example, the tubesheets are internally cooled with coolant in lieu of refractory and / or ceramic tube ferrules. Boiling fluid on the shell side of the heat recoveryexchanger can keep the metal temperature at desirable temperatures - preventing or reducing differential expansion. Transferring heat from the one or more products to the coolant may include vaporizing the coolant. In one example, the boiling point of the coolant is below about 500 °C. In another example, the boiling point of the coolant is below about 400 °C. In yet another example, the boiling point of the coolant is below about 300 °C. The coolant is generally capable of service without molecules breaking down or without producing undesirable film boiling. The coolant can be transferred out of vessel 110 using a thermosiphon system. In one example, the coolant may be utilized to transfer heat to an organic Rankine cycle system (e.g., organic Rankine cycle system 550) (discussed in further detail in FIG. 5).

[0065] Importantly, recovery of excess heat not only includes indirectly exchanging heat between the one or more products and the one or more reactants, but the recovery of excess heat can include heat exchange with a coolant (e.g., heat transfer fluid, such as water). For example, produced gas(es) can be quenched (e.g., using a water boiler) to produce steam. Quenching can be performed using a heat exchanger. Quenching the produced gas(es) reduces the produced gas(es) temperature to reduce or prevent corrosion to one or more portions of the catalytic reactor, while using the fluid (e.g., steam) to transfer heat to a different portion of a chemical production process, such as a portion other than the catalytic reactor. Examples of other portions of the chemical production process include a heat exchanger, such as a reactant feed heat exchanger for a distinct reaction. By using steam to transfer heat to a different portion of a chemical production process, overall energy efficiency is improved.

[0066] In one non-limiting example, the coldest temperature reactant gases are utilized to cool the portion of first reaction conduit 120 containing the hottest temperature product gases. Further, heat levels can be controlled throughout catalytic reactor 100. For example, metal materials of catalytic reactor 100 can be actively cooled to below metal creep temperatures by much cooler gases or dedicated coolants. The heat levels can be controlled by increasing the heating coefficient and dampening the cooling coefficient, or by decreasing the heating coefficient and increasing the cooling coefficient.

[0067] FIG. 2A illustrates a portion of catalytic reactor 100, according to some embodiments. FIG. 2A illustrates first heating element 122, first tubular structure 124, first helical fin structure 126, first reaction conduit inlet 130, first reaction conduit interior surface132, first reaction conduit exterior surface 134, and first internal reaction volume 136. As shown in the enlarged view, distance 221 is the distance between an outer edge 223 of helical fin structure 126 and first reaction conduit interior surface 132. For example, distance 221 is generally greater than 0 cm. The distance 221 between the outer edge 223 and first reaction conduit interior surface 132 can promote the cooling flow of the reactants to keep the walls of first reaction conduit 120 below the metal creep temperature. Distance 221 can be tuned to promote efficient heat transfer to bulk fluid in first internal reaction volume 136 while keeping the material used for first reaction conduit 120 below an undesirable temperature.

[0068] In one example, distance 221 ranges from about 0.1 mm to about 5 mm. In another example, distance 221 ranges from about 0.5 mm to about 4 mm. In yet another example, distance 221 ranges from about 1 mm to about 2 mm. Distance 221 may be less than 5 mm. Distance 221 may be greater than 0.1 mm. Distances of the present disclosure for distance 221 can be important for maintaining the temperature of bulk fluid flowing through first internal reaction volume 136 near the temperature of first helical fin structure 126 that is adjacent to the flowing bulk fluid.

[0069] FIG. 2B illustrates a side view of a first reaction conduit, according to some embodiments. First reaction conduit 120 is shown with various sections (A-A, B-B, and C-C). Section A-A is generally near distal end 195 of catalytic reactor 100, and section C-C is generally near proximal end 193 of catalytic reactor 100. FIG. 2C illustrates a section view of a portion of the first reaction conduit, according to some embodiments. The view in FIG. 2C is from section B-B in FIG. 2B. FIG. 2C illustrates first tubular structure 124, first helical fin structure 126, first reaction conduit inlet 130, first reaction conduit interior surface 132, first reaction conduit exterior surface 134, and first internal reaction volume 136. One or more reactants enter first internal reaction volume 136 via first reaction conduit inlet 130. As the one or more reactants travel around first tubular structure 124 and traverse the first helical fin structure 126, the one or more reactants are heated and the catalytic conversion to products begins. As discussed, first helical fin structure can include a single helix or a double helix structure or a triple helix structure.

[0070] FIG. 2D illustrates a section view of a portion of the first reaction conduit 120, according to some embodiments. The view in FIG. 2D is from section C-C in FIG. 2B. FIG. 2Dillustrates first tubular structure 124, first helical fin structure 126, first reaction conduit interior surface 132, first reaction conduit exterior surface 134, and first reaction conduit outlet 182. As shown, first tubular structure 124 and first helical fin structure 126 can extend throughout the length of first reaction conduit 120. The portion shown in FIG. 2D can be positionable adjacent to one or more inlets, such as first vessel inlet 112 and / or second vessel inlet 114, of vessel 110. First reaction conduit outlet 182 is sufficient for one or more reaction products to exit first reaction conduit 120. FIG. 2E illustrates an end view of the first reaction conduit 120, according to some embodiments. The end view in FIG. 2E is shown at the end of first reaction conduit 120 adjacent to first reaction conduit outlet 182. While first heating element 122 is generally positionable within first tubular structure 124, and first tubular structure 124 generally surrounds first heating element 122, first heating element 122 is not shown in FIG. 2E.

[0071] FIG. 2F illustrates a portion of catalytic reactor 100, according to some embodiments. FIG. 2F illustrates an example configuration of baffles 115 and illustrates how the reactant(s) can follow the torturous path to the first reaction conduit inlet 130 of first reaction conduit 120. In one example, baffles 115 includes a plurality of baffles. In another example, baffle 115 includes at least one of a disc type baffle and a donut type baffle. Baffle 115 may include one or more cutouts for the one or more reactants to flow through. Baffle 115 can be positioned adjacent to an exterior surface of first reaction conduit 120, second reaction conduit 150, third reaction conduit 160, and / or fourth reaction conduit 170. In one example, baffle 115 is in contact with interior vessel surface 118. As shown in FIG. 2F, baffles 115 include disc type baffle and a donut type baffle, and the disc type baffles and donut type baffles are configured in an alternating configuration to promote efficient heat transfer of excess heat to the one or more reactants. Baffles 115 can cause the flow of reactant(s) along either path reactant flow path 117 and / or reactant flow path 119 to flow across first reaction conduit 120 as opposed to along (e.g. axially) first reaction conduit 120. This flow orientation can improve heat transfer efficiency.

[0072] FIG. 3 illustrates catalytic reactor 300, according to some embodiments. Catalytic reactor 300 includes first vessel inlet 112, second vessel inlet 114, baffle 115, first reaction conduit 120, first heating element 122, reactor tubesheet 180, and vessel outlet 390. Catalytic reactor 300 can further include one or more of disc baffle 304, first coolant heat transfer fluid (HTF) inlet 306A, second coolant heat transfer fluid inlet 306B, girth flange 307, heatingelement tubesheet 309, girth flange 310, electricity distribution chamber 311, girth flange 312, cover plate 313, jacketed syngas chamber 314, girth flange 315, tubesheet coolant transfer conduit 316, jacket coolant HTF inlet 317A, jacket coolant HTF inlet 317B, jacket coolant HTF outlet 318A, jacket coolant HTF outlet 318B, girth flange 319, tubesheet 320, heat recovery exchanger 380, heat recovery shell side inlet 321A, heat recovery shell side inlet 321B, heat recovery product conduit 322, heat recovery shell side outlet 323 A, heat recovery shell side outlet 323B, heat recovery exchanger tubesheet 324, girth flange 325, and heat recovery exchanger product outlet head 326. One or more features and / or configurations of catalytic reactor 300 can be utilized in catalytic reactor 100. Jacketed syngas chamber 314 can be used for transferring heat from produced gas(es) (such as syngas) to one or more coolants. Accordingly, jacketed syngas chamber 314 can promote reduction of produced gas(es) temperature, reducing or preventing metal corrosion and metal creep. Heat recovery exchanger 380 can be in fluid communication with jacketed syngas chamber 314. Heat recovery exchanger 380 is capable of transferring heat from produced gases (such as syngas) to one or more coolants. The heat recover exchanger 380 can receive produced gases from jacketed syngas chamber 314.

[0073] FIG. 4 illustrates method 400 for performing a catalytic reaction, according to some embodiments. Method 400 includes one or more of the following steps (with various orders possible):

[0074] A catalytic reactor is utilized 410. The catalytic reactor includes catalytic reactors of the present disclosure, such as catalytic reactor 100 or catalytic reactor 300. The catalytic reactor utilized 410 can include one or more features and / or configurations of catalytic reactor 100 and / or catalytic reactor 300.

[0075] One or more reactants are introduced 420 to the vessel (e.g., vessel 110) through the at least one vessel inlet (e.g., first vessel inlet 112 and / or second vessel inlet 114). In one example, the one or more reactants include at least one of carbon dioxide and hydrogen. In another example, the one or more reactants include at least one of water and methane. In one example, the one or more reactants are introduced to the vessel (e.g., vessel 110) at a temperature below about 500 °C. In another example, the one or more reactants are introduced to the vessel (e.g., vessel 110) at a temperature below about 400 °C. In another example, the one or more reactants are introduced to the vessel (e.g., vessel 110) at a temperature below about 200 °C.Introducing 420 may include cooling at least a portion of the first reaction conduit exterior surface (e.g., first reaction conduit exterior surface 134) with the one or more reactants by traversing the one or more reactants across at least a portion of the first reaction conduit exterior surface, prior to introducing the one or more reactants to the first internal reaction volume (e.g. first internal reaction volume 136).

[0076] Electricity is provided 430 to the heating element, such as a first electric resistance heater (e.g., first heating element 122). In one example, electricity can be provided continuously. In another example, electricity is provided in an intermittent operation. Electricity may be at least partially provided by an organic Rankine cycle system. The organic Rankine cycle system 550 is illustrated in further detail in FIG. 5. Electricity may be provided prior to, concurrently, and / or after introducing 420. Electricity may be provided prior to, concurrently, and / or after introducing 440. The one or more reactants are introduced 440 to the first internal reaction volume (e.g., first internal reaction volume 136).

[0077] Heat is transferred 450 from the first electric resistance heater (e.g., first heating element 122) to the one or more reactants and the one or more reactants are contacted with the catalytic material sufficient to form one or more products. In one example, the one or more reactants are contacted with the catalytic material at a temperature above 300 °C. In another example, the one or more reactants are contacted with the catalytic material at a temperature above 400 °C. In yet another example, the one or more reactants are contacted with the catalytic material at a temperature above 500 °C. In one example, transferring 450 includes maintaining a temperature gradient along an axial direction (e.g., extension 138) of the first reaction conduit (e g., first reaction conduit 120).

[0078] Method 400 may further include maintaining a temperature of one or more materials of the first reaction conduit (e.g., first reaction conduit 120) below a creep temperature of the one or more materials. Controlling the heat levels throughout the reactor (e.g., catalytic reactor 100 or catalytic reactor 300) to operate below the creep temperature of the metal is important for avoiding metal fatigue and limiting metal material exposed to reaction products between 450 °C and 800 °C to avoid highly corrosive metal dusting.

[0079] Method 400 may further include transferring heat from the one or more products to a coolant. Transferring heat from the one or more products to the coolant may include vaporizingthe coolant. In one example, the boiling point of the coolant is below about 500 °C. In another example, the boiling point of the coolant is below about 400 °C. In yet another example, the boiling point of the coolant is below about 300 °C. The coolant can be transferred out of the vessel using a thermosiphon system. Method 400 may further include transferring heat to an organic Rankine cycle system (e.g., organic Rankine cycle system 550). In one example, electricity produced by the organic Rankine cycle system 550 can be provided to the heating element(s) 122 of the catalytic reactor (e.g., catalytic reactor 100 or catalytic reactor 300). For example, electricity produced by the organic Rankine cycle system 550 can be provided to the first heating element 122. The organic Rankine cycle system 550 is illustrated in further detail in FIG. 5

[0080] One or more products are transferred 460 out of the vessel (e.g., vessel 110) through the at least one vessel outlet. As discussed, prior to exiting the vessel (e.g., vessel 110), the one or more products may exchange heat with the one or more reactants. In one example, the one or more products include carbon monoxide. In another example, the one or more products include at least one of carbon monoxide, hydrogen, and water. In one example, the one or more products exit the vessel (e.g., vessel 110) at a temperature below about 600 °C. In another example, the one or more products exit the vessel (e.g., vessel 110) at a temperature below about 500 °C. In yet another example, the one or more products exit the vessel (e.g., vessel 110) at a temperature below about 400 °C.

[0081] FIG. 5 illustrates system 500 including a catalytic reactor, according to some embodiments. System 500 includes catalytic reactor 502 and organic Rankine cycle system 550. Catalytic reactor 502 includes catalytic reactors of the present disclosure, such as catalytic reactor 100 or catalytic reactor 300. FIG. 5 shows reactant inlet stream 510, electricity 520, product stream 530, coolant outlet stream 540, coolant inlet stream 560, and product electricity 570.

[0082] In one example, inlet stream 510 includes at least carbon dioxide and hydrogen, and product stream 530 includes carbon monoxide and water. In another example, inlet stream 510 includes at least methane and water, and product stream 530 includes carbon monoxide and hydrogen. Inlet stream 510 may include hydrogen from an electrolysis system. Product stream 530 may be transferred to downstream processing units for the production of alcohols andsyncrude derived products. Coolant outlet stream 540 generally includes a coolant of the present disclosure, and this coolant may be in the form of a vapor in coolant outlet stream 540. In one example, the boiling point of the coolant is below about 500 °C. In another example, the boiling point of the coolant is below about 400 °C. In yet another example, the boiling point of the coolant is below about 300 °C. Electricity 520 is provided to one or more heating elements 122 in catalytic reactor 502.

[0083] Coolant outlet stream 540 is transferred to organic Rankine cycle system 550. In one example, coolant is transferred using a thermosiphon system. Coolant is generally used to provide heat energy to organic Rankine cycle system 550, and this coolant can be in the form of a vaporized coolant. By transferring high energy coolant to the organic Rankine cycle system 550, a turbine can be utilized to produce electrical energy from high pressure fluids. Therefore, product electricity 570 can be provided from organic Rankine cycle system 550 to catalytic reactor 502. Lower pressure fluid exiting the turbine can be transferred to a condenser, and the condenser can produce a liquid. Therefore, the coolant that has transferred heat to organic Rankine cycle system 550 can be cooled and condensed, and the condensed coolant can be transferred back to catalytic reactor 502. The condensed coolant can be transferred to catalytic reactor 502 using a pump. The coolant can be utilized for cooling one or more tubesheets 180 in catalytic reactor 502.

[0084] Importantly, operating catalytic reactor 502 in combination with organic Rankine cycle system 550 can efficiently reduce the operating temperature of materials and / or products in catalytic reactor 502 while using recovered heat to produce electricity 570. This electricity 570 can be utilized for heating elements 122 in catalytic reactor 502 and / or other portions of the energy conversion process. Further, catalytic reactor 502 can also be utilized in an intermittent energy supply environment. For example, during a period of a power supply outage, a valve may be utilized to reduce or prevent the flow of product fluid, while a thermosiphon system can be utilized to control the transfer of coolant from catalytic reactor 502 to organic Rankine cycle system 550. Thus, organic Rankine cycle system 550 can continue to provide electricity to catalytic reactor 502 to optimize performance during the gradual reduction of temperatures in catalytic reactor 502.Discussion of Possible Embodiments

[0085] Clause 1. A catalytic reactor, including: a vessel having at least one vessel inlet and at least one vessel outlet; a first reaction conduit positioned within the vessel and having a first reaction conduit inlet, a first reaction conduit interior surface, a first internal reaction volume, and a first reaction conduit exterior surface, wherein a catalytic material is positionable within the first reaction conduit; and a first electric resistance heater at least partially positioned within the first reaction conduit, wherein the first electric resistance heater is physically separated from the first internal reaction volume.

[0086] The catalytic reactor of the preceding paragraph can optionally include, additionally and / or alternatively any one or more of the following features, configurations and / or additional components.

[0087] Clause 2. The catalytic reactor of clause 1, wherein the first electric resistance heater is coaxially arranged with the first reaction conduit.

[0088] Clause 3. The catalytic reactor of clause 1 or 2, further including a first tubular structure coaxially arranged with the first reaction conduit and at least partially positioned within the first reaction conduit, wherein the first electric resistance heater is enclosed by the first tubular structure.

[0089] Clause 4. The catalytic reactor of any one of clauses 1-3 further including a first helical fin structure, wherein the first helical fin structure is positioned between the first reaction conduit interior surface and the first electric resistance heater.

[0090] Clause 5. The catalytic reactor of clause 4, wherein a distance from an outer edge of the first helical fin structure to the first reaction conduit interior surface ranges from about 0.5 mm to about 4 mm.

[0091] Clause 6. The catalytic reactor of clause 4, wherein the first helical fin structure includes a multi-helix fin structure.

[0092] Clause 7. The catalytic reactor of clause 4, wherein the first helical fin structure includes helical fins in contact with a first tubular structure coaxially arranged with the first reaction conduit.

[0093] Clause 8. The catalytic reactor of clause 7, wherein the first internal reaction volume is defined by the first reaction conduit interior surface and the first helical fin structure, and wherein the first electric resistance heater is positionable within the first tubular structure.

[0094] Clause 9. The catalytic reactor of any one of clauses 1-8, including a reactant flow path in fluid communication with the at least one vessel inlet and the first reaction conduit inlet, wherein the reactant flow path is at least partially defined by an interior vessel surface of the vessel and the first reaction conduit exterior surface.

[0095] Clause 10. The catalytic reactor of any one of clauses 1-9 further including a second reaction conduit having a second reaction conduit inlet, a second reaction conduit interior surface, a second internal reaction volume, and a second reaction conduit exterior surface.

[0096] Clause 11. The catalytic reactor of clause 10 further including a second electric resistance heater positioned within the second reaction conduit.

[0097] Clause 12. The catalytic reactor of clause 11 further including a second helical fin structure, wherein the second helical fin structure is positioned between the second reaction conduit interior surface and the second electric resistance heater.

[0098] Clause 13. The catalytic reactor of any one of clauses 1-12 further including at least one baffle positioned within the vessel, wherein the at least one baffle is adjacent to the first reaction conduit exterior surface.

[0099] Clause 14. The catalytic reactor of any one of clauses 1-13, wherein the at least one vessel inlet is configured to introduce fluid into the vessel in a substantially perpendicular flow direction with respect to a first axis of extension of the first reaction conduit.

[0100] Clause 15. The catalytic reactor of any one of clauses 1-14, further including a reactor tubesheet in contact with at least a portion of the first reaction conduit, wherein the reactor tubesheet is positioned adjacent to a first reaction conduit outlet, and wherein the first reaction conduit is configured for axial expansion.

[0101] Clause 16. A catalytic reactor, including: a vessel having at least one vessel inlet and at least one vessel outlet; a first reaction conduit positioned within the vessel and having a first reaction conduit inlet, a first reaction conduit interior surface, a first internal reaction volume, and a first reaction conduit exterior surface, wherein a catalytic material is positionable within the first reaction conduit; a first tubular structure coaxially arranged with the first reaction conduit and at least partially positioned within the first reaction conduit; a first helical fin structure positioned between the first reaction conduit interior surface and the first tubularstructure; and a first electric heater element at least partially positioned within the first tubular structure.

[0102] The catalytic reactor of the preceding paragraph can optionally include, additionally and / or alternatively any one or more of the following features, configurations and / or additional components.

[0103] Clause 17. The catalytic reactor of clause 16, wherein the first electric heater element includes an electric resistance heater and is enclosed by the first tubular structure.

[0104] Clause 18. The catalytic reactor of clause 16, wherein the first helical fin structure is in contact with the first tubular structure.

[0105] Clause 19. The catalytic reactor of any one of clauses 16-18, wherein the at least one vessel inlet is configured to introduce fluid into the vessel in a substantially perpendicular flow direction with respect to a first axis of extension of the first reaction conduit.

[0106] Clause 20. A method of performing a catalytic reaction, including: utilizing a catalytic reactor, including: a vessel having at least one vessel inlet and at least one vessel outlet; a first reaction conduit positioned within the vessel and having a first reaction conduit inlet, a first reaction conduit interior surface, a first internal reaction volume, and a first reaction conduit exterior surface, wherein a catalytic material is positionable within the first reaction conduit; and a first electric resistance heater at least partially positioned within the first reaction conduit, wherein the first electric resistance heater is physically separated from the first internal reaction volume; introducing one or more reactants to the vessel through the at least one vessel inlet; providing electricity to the first electric resistance heater; introducing the one or more reactants to the first internal reaction volume; and transferring heat from the first electric resistance heater to the one or more reactants and contacting the one or more reactants with the catalytic material sufficient to form one or more products.

[0107] The method of the preceding paragraph can optionally include, additionally and / or alternatively any one or more of the following features, configurations and / or additional components.

[0108] Clause 21. The method of clause 20, wherein the one or more reactants are introduced to the vessel at a temperature below about 400 °C.

[0109] Clause 22. The method of clause 20, wherein the one or more reactants are contacted with the catalytic material at a temperature above 400 °C.

[0110] Clause 23. The method of any one of clauses 20-22, wherein the one or more products are transferred out of the vessel at a temperature below about 400 °C.

[0111] Clause 24. The method of any one of clauses 20-23, wherein electricity is provided in an intermittent operation.

[0112] Clause 25. The method of any one of clauses 20-24 including maintaining a temperature gradient along an axial direction of the first reaction conduit.

[0113] Clause 26. The method of any one of clauses 20-25 including cooling the first reaction conduit exterior surface with the one or more reactants by traversing the one or more reactants across at least a portion of the first reaction conduit exterior surface, prior to introducing the one or more reactants to the first internal reaction volume.

[0114] Clause 27. The method of any one of clauses 20-25 further including transferring heat from the one or more products to a coolant, wherein transferring heat to the coolant includes vaporizing the coolant.

[0115] Clause 28. The method of any one of clauses 20-27 including maintaining a temperature of one or more materials of the first reaction conduit below a creep temperature of the one or more materials.

[0116] Clause 29. The method of any one of clauses 20-28 further including transferring heat to an organic Rankine cycle system.

[0117] Clause 30. The method of clause 29 further including providing electricity from the organic Rankine cycle system to the first electric resistance heater.

[0118] While the disclosure has been described with reference to an exemplary embodiment s), it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted for elements thereof without departing from the scope of the embodiment(s). In addition, many modifications may be made to adapt a particular situation or material to the teachings of the embodiment(s) without departing from the essential scope thereof. Therefore, it is intended that the disclosure is not limited to the disclosed embodiment(s), but that the disclosure will include all embodiments falling within the scope ofthe appended claims. Various examples have been described. These and other examples are within the scope of the following claims.

Claims

CLAIMS:

1. A catalytic reactor, comprising: a vessel having at least one vessel inlet and at least one vessel outlet; a first reaction conduit positioned within the vessel and having a first reaction conduit inlet, a first reaction conduit interior surface, a first internal reaction volume, and a first reaction conduit exterior surface, wherein a catalytic material is positionable within the first reaction conduit; and a first electric resistance heater at least partially positioned within the first reaction conduit, wherein the first electric resistance heater is physically separated from the first internal reaction volume.

2. The catalytic reactor of claim 1 , wherein the first electric resistance heater is coaxially arranged with the first reaction conduit.

3. The catalytic reactor of claim 1 or 2, further including a first tubular structure coaxially arranged with the first reaction conduit and at least partially positioned within the first reaction conduit, wherein the first electric resistance heater is enclosed by the first tubular structure.

4. The catalytic reactor of any one of claims 1-3 further comprising a first helical fin structure, wherein the first helical fin structure is positioned between the first reaction conduit interior surface and the first electric resistance heater.

5. The catalytic reactor of claim 4, wherein a distance from an outer edge of the first helical fin structure to the first reaction conduit interior surface ranges from about 0.5 mm to about 4 mm.

6. The catalytic reactor of claim 4, wherein the first helical fin structure includes a multihelix fin structure.

7. The catalytic reactor of claim 4, wherein the first helical fin structure includes helical fins in contact with a first tubular structure coaxially arranged with the first reaction conduit.

8. The catalytic reactor of claim 7, wherein the first internal reaction volume is defined by the first reaction conduit interior surface and the first helical fin structure, and wherein the first electric resistance heater is positionable within the first tubular structure.

9. The catalytic reactor of any one of claims 1-8, including a reactant flow path in fluid communication with the at least one vessel inlet and the first reaction conduit inlet, wherein the reactant flow path is at least partially defined by an interior vessel surface of the vessel and the first reaction conduit exterior surface.

10. The catalytic reactor of any one of claims 1-9 further comprising a second reaction conduit having a second reaction conduit inlet, a second reaction conduit interior surface, a second internal reaction volume, and a second reaction conduit exterior surface.

11. The catalytic reactor of claim 10 further comprising a second electric resistance heater positioned within the second reaction conduit.

12. The catalytic reactor of claim 11 further comprising a second helical fin structure, wherein the second helical fin structure is positioned between the second reaction conduit interior surface and the second electric resistance heater.

13. The catalytic reactor of any one of claims 1-12 further comprising at least one baffle positioned within the vessel, wherein the at least one baffle is adjacent to the first reaction conduit exterior surface.

14. The catalytic reactor of any one of claims 1-13, wherein the at least one vessel inlet is configured to introduce fluid into the vessel in a substantially perpendicular flow direction with respect to a first axis of extension of the first reaction conduit.

15. The catalytic reactor of any one of claims 1-14, further comprising a reactor tubesheet in contact with at least a portion of the first reaction conduit, wherein the reactor tubesheet is positioned adjacent to a first reaction conduit outlet, and wherein the first reaction conduit is configured for axial expansion.

16. A catalytic reactor, comprising: a vessel having at least one vessel inlet and at least one vessel outlet; a first reaction conduit positioned within the vessel and having a first reaction conduit inlet, a first reaction conduit interior surface, a first internal reaction volume, and a first reaction conduit exterior surface, wherein a catalytic material is positionable within the first reaction conduit; a first tubular structure coaxially arranged with the first reaction conduit and at least partially positioned within the first reaction conduit; a first helical fin structure positioned between the first reaction conduit interior surface and the first tubular structure; and a first electric heater element at least partially positioned within the first tubular structure.

17. The catalytic reactor of claim 16, wherein the first electric heater element includes an electric resistance heater and is enclosed by the first tubular structure.

18. The catalytic reactor of claim 16, wherein the first helical fin structure is in contact with the first tubular structure.

19. The catalytic reactor of any one of claims 16-18, wherein the at least one vessel inlet is configured to introduce fluid into the vessel in a substantially perpendicular flow direction with respect to a first axis of extension of the first reaction conduit.

20. A method of performing a catalytic reaction, comprising: utilizing a catalytic reactor, including: a vessel having at least one vessel inlet and at least one vessel outlet; a first reaction conduit positioned within the vessel and having a first reaction conduit inlet, a first reaction conduit interior surface, a first internal reaction volume, and a first reaction conduit exterior surface, wherein a catalytic material is positionable within the first reaction conduit; and a first electric resistance heater at least partially positioned within the first reaction conduit, wherein the first electric resistance heater is physically separated from the first internal reaction volume; introducing one or more reactants to the vessel through the at least one vessel inlet; providing electricity to the first electric resistance heater; introducing the one or more reactants to the first internal reaction volume; and transferring heat from the first electric resistance heater to the one or more reactants and contacting the one or more reactants with the catalytic material sufficient to form one or more products.

21. The method of claim 20, wherein the one or more reactants are introduced to the vessel at a temperature below about 400 °C.

22. The method of claim 20, wherein the one or more reactants are contacted with the catalytic material at a temperature above 400 °C.

23. The method of any one of claims 20-22, wherein the one or more products are transferred out of the vessel at a temperature below about 400 °C.

24. The method of any one of claims 20-23, wherein electricity is provided in an intermittent operation.

25. The method of any one of claims 20-24 including maintaining a temperature gradient along an axial direction of the first reaction conduit.

26. The method of any one of claims 20-25 including cooling the first reaction conduit exterior surface with the one or more reactants by traversing the one or more reactants across at least a portion of the first reaction conduit exterior surface, prior to introducing the one or more reactants to the first internal reaction volume.

27. The method of any one of claims 20-25 further comprising transferring heat from the one or more products to a coolant, wherein transferring heat to the coolant includes vaporizing the coolant.

28. The method of any one of claims 20-27 including maintaining a temperature of one or more materials of the first reaction conduit below a creep temperature of the one or more materials.

29. The method of any one of claims 20-28 further comprising transferring heat to an organic Rankine cycle system.

30. The method of claim 29 further comprising providing electricity from the organic Rankine cycle system to the first electric resistance heater.

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