A reactor for production of hydrocarbons and synthesis gas

Abstract

A reactor (100) is proposed. The reactor (100) is configured for production of hydrocarbons and synthesis gas via partial oxidation, comprising a burner block (130) and a fireroom (140). The fireroom (140) has a plurality of walls forming a lateral surface of a hexagonal prism or a truncated hexagonal pyramid.

Description

[0001] 240327W001

[0002] A reactor for production of hydrocarbons and synthesis gas

[0003] Technical Field

[0004] The present invention discloses reactor configured for production of hydrocarbons and synthesis gas via partial oxidation and a method for manufacturing a reactor.

[0005] Background art

[0006] The process of production of hydrocarbons and synthesis gas via partial oxidation are typically performed in a reactor, in which a stream comprising the hydrocarbon and a stream comprising the oxygen are fed to the reactor, which typically is composed of a mixing unit, a burner unit, a fireroom, and a quench unit. Examples of reactors are described in Ullmanns Encyclopedia of Industrial Chemistry, Passler, P., Hefner, W., Buckl, K., Meinass, H., Meiswinkel, A., Wernicke, H.-J., Ebersberg, G., Muller, R., Bassler, J., Behringer, H. and Mayer, D. (2011), Acetylene, page 287 or US 005824834A. One example of such a partial oxidation in the high-temperature range is the preparation of acetylene and synthesis gas by partial oxidation of hydrocarbons, e.g. as described, for example, in DE 875198, DE 1051845, DE1057094 and DE 4422815. These documents explain the mixer / burner block / fireroom / quench combinations typically used for the BASF-Sachsse-Bartholome acetylene process-referred to hereinafter, when reference is being made to the combination, simply as "reactor".

[0007] US 2012 / 0119150 A1 describes a typically process. The raw materials, for example natural gas and oxygen, are heated separately, typically up to 600° C. In a mixing zone, the reactants are mixed intensively and, after flowing through a burner block, reacted exothermically. In these cases, the burner block consists of a particular number of parallel channels in which the flow velocity of the ignitable oxygen / natural gas mixture is higher than the flame velocity (reaction rate, conversion rate), to prevent the flame from penetrating into the mixing zone. The metallic burner block is cooled to withstand the thermal stresses. The acetylene reactors being used on the present production scale are notable for their cylindrical geometry in the fireroom. The burner block preferably has hexagonally arranged passage bores. In one embodiment, for example, 127 bores of internal diameter 27 mm are arranged hexagonally on a circular base cross section with diameter approx. 500 mm. In general, the channel diameters used are of diameter about 19 to 27 mm. The downstream fireroom in which the flame of the acetylene-forming partial oxidation reaction is stabilized is likewise of cylindrical cross section, is water-cooled and corresponds in terms of appearance to that of a short tube (for example of diameter 180 to 533 mm 240327W001

[0008] - 2 - and of length 380 to 450 mm). At the height of the surface of the burner block on the fireroom side, auxiliary oxygen is supplied to the reaction space. This ensures flame stabilization. The entire burner composed of burner block and fireroom is installed at the top flange of a quench vessel that has a large cross section. At the height of the end of the fireroom, outside the circumference thereof, quench nozzles are installed in one or more quench distributor rings, which atomize the quench medium, for example water or oil, with or without the aid of an atomization medium, and inject the reaction gases leaving the fireroom approximately at right angles to the main flow direction. This direct quench has the task of cooling the reacting flow extremely rapidly to approx. 100° C. (water quench) and 200° C. (oil quench), such that further reactions, especially the degradation of acetylene formed, are frozen. The range and distribution of the quench jets is ideally such that a very substantially homogeneous thermal distribution is achieved within minimum time.

[0009] The acetylene reactors used on the current production scale are notable for a cylindrical geometry of the fireroom. The feedstocks are premixed by means of a diffuser and supplied, with avoidance of back-mixing, to the burner block via passage bores in a hexagonal arrangement. In the known processes, the feedstocks are premixed in the mixing diffuser in a relatively large volume and with high preheating temperatures.

[0010] The industrial process forms not only acetylene but essentially hydrogen, carbon monoxide and soot. The soot particles formed in the flame front can adhere to the fireroom walls (fireroom interior walls) as well as at the bottom side of the burner block. Soot adherences then result in growth, deposition and baking-on of coke layers, which adversely affects the effectiveness of the process. In the existing production processes with oil and water quenching, these deposits are periodically removed by mechanical cleaning devices (stoker units) from the fireroom walls and the burner block bottom side. For this purpose, a complex control of the stoker units is necessary (Ullmann's Encyclopedia of Industrial Chemistry, 2011 , pages 288 and the following) and, in addition, the particular use time of the mechanism is limited by the thermal stress in the fireroom.

[0011] There has been no lack of attempts to avoid the disadvantage of the baking of coke layers onto the fireroom interior wall. For instance, the teaching of DE 2307300 discloses the injection of a gaseous substance into the reactor in a region between maximum temperature and quenching site (claim 1). This is intended to lead to reactions between the gases added and free radicals, which is intended to reduce coke formation (description, page 8, second paragraph). DE 3904330 A1 describes a process for preparing acetylene black by thermal decomposition of 240327W001

[0012] - 3 - acetylene. It is mentioned in this process, which differs significantly from the process for preparing acetylene (e.g. no partial oxidation), that an inert gas stream is optionally introduced. DE 1148229 describes a process for operating pyrolysis chambers for treatment of hydrocarbons, wherein purging with steam is provided and cooling of the wall is supposed to lead to a water curtain (claim 1). No further information is given about the way in which the purging is executed. The process presented is not a partial oxidation (POx), the purge medium introduced is liquid water, and additional admixing of an oxidizing agent (e.g. oxygen) with the purge medium is not provided. Furthermore, a purge medium is injected only at a maximum of one site in the axial profile of the pyrolysis chamber. According to the teaching of DE 1250424, a process for preparing acetylene is disclosed, in which steam is conducted along the interior wall. However, there is no further information about specific embodiments. Moreover, although multi-level feeding of a purge stream is disclosed in FIGS. 3 and 4, these solutions have a significant change in the free cross section of the combustion space over the height of the combustion chamber; viewed in flow direction of the product, a significant enlargement is observed here. This leads, however, to inhomogeneities in the reaction as a result of enhanced back-mixing in the fireroom, which impairs the effectiveness of the process. In addition, the purge medium according to this teaching, is superheated to 600-1000°C., which leads to significant problems in the material stability of the feed lines and to increased supply costs. This is additionally a different combustion concept of staged combustion with "cracked gas" injection (not conventional POx according to BASF- Sachsse-Bartholome Process). According to the method, the fluid velocity of the purge exceeds the mean flue gas velocity in the reactor, which can lead to inhomogeneities in the boundary layer between the two flows and hence even to the suction of coke particles onto the fireroom interior wall. According to this teaching, the fireroom wall in process operation has a temperature of about 700°C., which can likewise lead to problems with material stability / selection. DE 2007997 describes how an oil film on the interior wall of the reaction chamber is supposed to prevent coking (page 2, first paragraph). However, an oil film in a fireroom tends to form coke per se. Therefore, a hydrocarbon containing (mineral) oil can be ruled out as a purge medium given the present challenge.

[0013] The processes disclosed in the documents cited for prevention or reduction of unwanted coke formation, however, are unsatisfactory with respect to effective use in the process for preparing acetylene. For instance, some of the documents, as explained, relate to other reactions where the conditions are quite different and there is no applicability. For instance, the partial oxidation in the process according to the invention is very demanding in terms of characteristics: the residence times play a particularly major role, the stoppage of the reaction must be very exact, and the addition of extraneous substances, including, for example, a purge gas or oxidizer, can 240327W001

[0014] - 4 - move the reaction very rapidly with respect to the site and also the rate thereof, thus leading to a yield loss.

[0015] Moreover, WO 2012 / 062784 A1 describes a process for the production of acetylene in which the inner wall of the combustion chamber is covered with a purge gas flow, this purge gas flow is introduced by means of multi-stage feed lines and each of these feed lines is formed inside the combustion chamber in such a way that the orientation of the direction vector of the main flow of the fed purge gas stream deviates from the orientation of the direction vector of the main flow direction of the gas stream fed through the burner block at an angle of at most 10° (claim 1). Either oxygen, water vapor or mixtures thereof are used as the purging medium. The requirements for purging lead to a complex combustion chamber design which, in combination with the filigree purging gas distributor gaps (Figures 1-3), may represent a very expensive and error-prone system. Furthermore, the additional introduction of a non-inert purging medium may have a potentially negative impact on the efficiency of the process.

[0016] WO 2012 / 062584 A1 discloses a process for the production of acetylene, which is characterized in that the combustion chamber-side surface of the burner block is covered with a purge gas flow through additional holes through the burner block, (claim 1). Either oxygen, water vapor or mixtures thereof are used as the purging medium. The requirements for purging the burner block result in a complex burner block design. The additional introduction of a non-inert purging medium may have a potentially negative impact on the efficiency of the process.

[0017] WO2015 / 028539 A1 describes a way in which the supply of auxiliary oxygen to the burner block can be designed to achieve an even distribution of the oxygen.

[0018] US 2 998 465 describes a quench system of an acetylene burner.

[0019] EP 1 462 162 B1 describes a scale-up of a reactor comprising increasing the inner diameter of the reactor for increasing the throughput. The transition of the reaction chamber into the quenching region is in the form of a gap having a width of 2-200 mm.

[0020] Therefore, despite the advantageous reached as outlined above, there is still a need for improving the reactor for partial oxidation of hydrocarbons, which can prevent, in particular in a procedurally simple manner, of the baking and deposits of coke layers onto surface of the burner block facing the fireroom and the fireroom interior walls in order to prevent mechanically cleaning of these surfaces and, thus, a periodic cleaning using the thermally highly stressed and complex to control mechanical stoker unit. 240327W001

[0021] - 5 -

[0022] Problem to be solved

[0023] It is therefore an objective of the present invention to provide a reactor configured for production of hydrocarbons, especially acetylene, and synthesis gas via partial oxidation and a method for manufacturing a reactor which at least partially avoid the drawbacks and disadvantages of known reactors and methods. Specifically, it is desirable to provide a reactor which allow for preventing the need of using mechanical stoker units.

[0024] Summary

[0025] This problem is addressed by a reactor configured for production of hydrocarbons and synthesis gas via partial oxidation and a method for manufacturing a reactor with the features of the independent claims. Advantageous embodiments which might be realized in an isolated fashion or in any arbitrary combinations are listed in the dependent claims as well as throughout the specification.

[0026] In a first aspect, a reactor configured for production of hydrocarbons and synthesis gas via partial oxidation is disclosed.

[0027] The reactor comprises a burner block and a fireroom. The fireroom has a plurality of walls forming a lateral surface of a hexagonal prism or a hexagonal truncated pyramid.

[0028] The term “reactor” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to at least one device or system configured for carrying out and / or in which at least one chemical reaction and / or at least one partial reaction can take place. The chemical reaction may be an exothermic reaction. The reactor is configured for the production of hydrocarbons and synthesis gas via partial oxidation, in particular acetylene and synthesis gas by partial oxidation of hydrocarbons with oxygen. The BASF-Sachsse-Bartholome Process for the production of acetylene from natural gas has been known since 1950. With respect to the production of hydrocarbons and synthesis gas via partial oxidation reference is made to DE 875198, DE 1051845, DE1057094 and DE 4422815. The reactor may be a part of a partial oxidation acetylene plant. The reactor may be reactor system comprising a plurality of units such as mixing unit, the burner block, the fireroom, and a quench unit. The term "system" as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or 240327W001

[0029] - 6 - customized meaning. The term specifically may refer, without limitation, to an arbitrary set of interacting or interdependent components parts forming a whole. Specifically, the components may interact with each other in order to fulfill at least one common function. The process of production of hydrocarbons may comprise pre-heating the raw materials, for example natural gas and oxygen, separately, typically up to 600° C in the case of natural gas. The raw materials may also be denoted as “feedstock” herein. The reactor, in particular the mixing unit, may comprise at least two inlets for feeding the raw materials from the respective source, e.g. a natural gas source and an oxygen gas source. The pre-heated raw materials may be fed into a mixing unit. The mixing unit may be configured for mixing the pre-heated raw materials. The mixing unit may be configured for mixing the reactants so rapidly that there are no domains with high oxygen concentrations and a directed flow inside the mixer is given. The mixing unit may be arranged on top of the burner block. The mixed and pre-heated raw materials may be ignited in the fireroom after flowing through the burner block and the resulting reaction gas is then cooled rapidly by using the quench unit. The fireroom may comprise at least one outlet for releasing the products, e.g. hydrocarbons and synthesis gas, to the quench unit. The mixing unit and / or the quench unit may be designed as described in Ullmanns Encyclopedia of Industrial Chemistry, Passler, P., Hefner, W., Buckl, K., Meinass, H., Meiswinkel, A., Wernicke, H.-J., Ebersberg, G., Muller, R., Bassler, J., Behringer, H. and Mayer, D. (2011), Acetylene, pages 287-293.

[0030] The term “burner block” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to a unit of the reactor configured for providing flames for initiating a flame reaction in the fireroom. This can allow for stabilizing the flames for the partial oxidation in the fireroom.

[0031] The burner block may comprise at least one burner flange and at least one burner plate. The term “burner plate” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to an element of the burner block comprising flow tubes. The term “burner flange” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to an element of the burner block configured for holding and / or positioning the burner plate. For example, the burner flange may be used for clamping the burner block between a mixing unit and a quench unit of the reactor. 240327W001

[0032] - 7 -

[0033] The burner plate and the burner flange may be designed as combined element or as separate elements.

[0034] The burner plate and the burner flange may be made of the same material or of different materials.

[0035] The burner block may have a cylindrical outer shape. The burner block, in particular the burner plate and / or the burner flange, may comprise stainless steel, high-temperature steel, stainless steel high-alloyed, high-temperature steel (superalloys) such as materials having the following material number 2.4816 (Alloy 600 available from Special Metals Corporation under the brand name Inconel), 2.4663 (Alloy 617), 2.4856 (Alloy 625), 2.4642 (Alloy 690), 2.4668 (Alloy 718), 2.4669 (Alloy X-750), 1.4958 (Alloy 800 H), 2.4973 (Rene 41), 2.4858 (Alloy 825), 2.4654 (Waspalloy), the following materials listed in DIN EN 10095:1999 “Heat resisting steels and nickel alloys” 1.4713, 1.4724, 1.4742, 1.4762, 1.4749, 1.4737 1.4878, 1.4828, 1.4835, 1.4833, 1.4845, 1.4841 , 1.4864, 1.4876, 1.4877, 1.4872, 1.4818, 1.4854, 1.4886, 1.4887, 1.4821 1.4512, 1.4510, 1.4509, 1.4301 , 1.4948, 1.4541 , 1.4941 , 1.4950, 1.4951 , 1.4362, the following materials listed in DIN EN 10028-2:2017 “Flat Products made of steels for pressure purposes - Part 2: Non-alloy and alloy steels with specified elevated temperature properties” 1.0345, 1.0425, 1.0481 , 1.0473, 1.5415, 1.5414, 1.6311 , 1.6368, 1.7335, 1.7336, 1.7380, 1.7375, 1.7362, 1.7703, 1.7767, 1.4903.

[0036] For example, the burner plate may be made from 2.4668 (Alloy 718) and the burner flange may be made from one or more of the following materials listed in DIN EN 10028-2:2017 “Flat Products made of steels for pressure purposes - Part 2: Non-alloy and alloy steels with specified elevated temperature properties” 1.0345, 1.0425, 1.0481 , 1.0473, 1.5415, 1.5414, 1.6311 , 1.6368, 1.7335, 1.7336, 1.7380, 1.7375, 1.7362, 1.7703, 1.7767, 1.4903.

[0037] The burner plate may comprise flow tubes. The term “flow tube” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to a channel or bore configured for fluid flow from one end of the channel or bore to the other side of the channel or bore. Unless otherwise stated, the terms channel and bore are used synonymously in the context of the present invention. In the context of the present invention, a bore is to be understood as a round or non-circular opening in or through a component. The burner block may be arranged between the mixing unit and the fireroom. In particular, one end of the flow tube may be arranged facing the mixing unit and the other end of the flow tube may be arranged facing the fireroom. The burner block may be configured such that the pre- 240327W001

[0038] - 8 - heated and mixed raw materials, also denoted as reaction materials, flow through the flow tubes from the mixing unit to the fireroom. The flow tubes may form a perforated burner plate.

[0039] The flow tubes may be arranged equally distributed in a hexagonal structure. The term “hexagonal structure” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to the hexagonal shape of an outer contour of the arrangement flow tubes in a top view on the burner plate. In a top view on the burner plate, the hexagonal structure may have a hexagonal outer contour. The flow tubes within the hexagonal structure may be arranged concentrically on hexagonal rows around a center of the burner block. A single flow tube may be arranged at the center of the burner block. The burner plate may comprise more than 127, preferably at least 169, flow tubes within the hexagonal structure. The distance between the flow tubes, i.e. a relative distance between two flow tubes, may be from 42 mm to 36 mm, preferred 38.8 mm. A distance between the most outer row of flow tubes of the hexagonal structure and the fireroom walls may be constant. It was found that sound emission of the reactor is strongly depending on reactor load and thereby gas flow velocity inside of the flow tubes. By lowering the distance between the tubes < 42 mm, on the one hand and adding an additional ring of tubes compared to known burner blocks on the other hand for maintaining the overall geometry of the burner block, the gas flow velocity inside the flow tubes can be reduced by approx. 20%. This can allow reducing sound emissions of the reactor and, hence, can ensure the plant’s legally approved sound emission limits finally.

[0040] For example, the flow tubes have a constant cross-sectional area. The cross-sectional area may be defined as area perpendicular to a center line of the flow tube. For example, the cross- sectional area that can be perpendicular to an imaginary center line through the center of the opening of the flow tube. The term “constant” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to constant within tolerances, e.g. manufacturing tolerances, such as within ± 10 %, preferably ± 5 %, more preferably ±1 %. The tolerances may be defined according to Rohre DIN EN C-Stahl I Technische Grundlagen (rff.de). The burner block may have a number of continuous channels.

[0041] For example, the flow tubes have a varying cross sectional area over the length of the flow tubes. Each of the flow tubes may be designed with a varying cross section over the tube length. For example, the flow tube may have at least one geometry selected from the group consisting of: a widening of the cross sectional area over the length of the flow tube, e.g. from 240327W001

[0042] - 9 - one end of the flow tube, e.g. the end facing the mixing unit, to the other end, e.g. facing the fireroom; a widening of the cross sectional area over parts of the length of the flow tube; a Venturi pipe, a diffusor; and the like.

[0043] The burner block may comprise openings facing the fireroom through which additional oxygen, denoted as auxiliary oxygen, may be fed into the reaction mixture. At these openings flames can form and initiate the flame reaction. The openings may be arranged between the flow tubes. The burner block may comprise at least one distribution ring, such as an annular space, and a connected volume for distributing the auxiliary oxygen to the openings, in particular in an evenly distributed manner. The auxiliary oxygen may be fed radially from the distribution ring into the volume. The arrangement of the distribution ring and connected volume may be designed as described in WO 2015 / 028539 as annular space and secondary space. The burner block may comprise further distribution rings, e.g. for axially providing with auxiliary oxygen. The radial and axial distribution of oxygen may be designed as described in WO 2012 / 062584, e.g. Figure 2.

[0044] The burner block may be water-cooled. The burner block may comprise a water-cooled burner plate, e.g. a water-cooled steel plate. The burner block may comprise an integrated water-cooling. The integrated water-cooling may comprise at least one water-cooling chamber. The watercooling chamber may be configured for distributing water at a defined temperature through the burner block, e.g. as described in Ullmanns Encyclopedia of Industrial Chemistry, Passler, P., Hefner, W., Buckl, K., Meinass, H., Meiswinkel, A., Wernicke, H.-J., Ebersberg, G., Muller, R., Bassler, J., Behringer, H. and Mayer, D. (2011), Acetylene, pages 287-293. Alternatively, the burner block may be non-water-cooled.

[0045] The term “fireroom” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to a unit of the reactor in which the exothermic reaction takes place. The reaction mixture after flowing through the burner block may enter the fireroom and may be brought to an exothermic reaction. Since hydrocarbon and oxygen are used as raw materials in the context of the present invention, acetylene may be mainly formed during this exothermic reaction. Hydrogen, carbon monoxide and a small amount of soot may be formed as by-products.

[0046] The fireroom has a plurality of walls. The walls of the fireroom may form a space or volume in which the exothermic direction can take place. The walls of the fireroom may delimit the fireroom. The fireroom has a plurality of walls forming a lateral surface of a hexagonal prism or a truncated hexagonal pyramid. The term “prism” as used herein is a broad term and is to be 240327W001

[0047] - 10 - given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to a polyhedron comprising an n-sided polygon base, a second base which is a translated copy of the first, and n other faces, which are all parallelograms, joining corresponding sides of the two bases. In case of a hexagonal prism n=6. The hexagonal prism may be open at the top base facing the burner block. The term “pyramid” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to a polyhedron formed by connecting a polygonal base and a point, called the apex. The term “truncated pyramid” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to a polygonal base at the bottom and a polygonal base at the top at a defined height. In case of a truncated hexagonal pyramid the polygonal top base and the polygonal bottom base are hexagons. The truncated hexagonal pyramid may be open at the top base facing the burner block. The walls of the fireroom may comprise flat plates. The flat plates may define the side faces of the prism or pyramid, respectively. The fireroom further may comprise edge walls or connecting walls configured for connecting the walls forming the side faces.

[0048] Thus, in comparison to known reactor designs, the present invention proposes redesigning the fireroom. Instead of a circular basic shape a hexagon can be used. With this approach the distance between the outer ring of flow tubes of the burner block and the wall of the fireroom is constant and minimized. This can allow minimizing hot gas recirculation zones close to the walls of the fireroom in which the coke is formed and can prevent coke deposits on the fireroom walls as well. With this directed flow conditions can be realized inside the fireroom which can allow preventing hot gas recirculation zones close to the walls of the fireroom in which the coke is formed and can prevent coke deposits on the fireroom walls as well. The decreased distance between the flames and wall of the fireroom may increase the heat transfer from the flame to the wall, which e.g. is water-cooled, and therefore quenches the reaction and acetylene formation in this area. To reduce the quenching a layer, in particular configured as an insulation layer, may be added to the fireroom to increase the wall temperature for reducing quenching. The hexagonal fireroom, in particular in combination of an oxygen-flushed burner block surface, can enable a stable operation of the acetylene reactors without stoker robots.

[0049] For example, the walls of the fireroom may be metal walls. The metal may be stainless steel. 240327W001

[0050] - 11 -

[0051] For example, the fireroom may be equipped with at least one layer at the inside. The term “inside” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to the side of the walls facing the space where the exothermic reaction can take place. The layer may be a cover and / or coating and / or sheet and may cover the surface of the walls facing the space where the exothermic reaction can take place. The layer at the inside may be refractory from -10 °C to 2680 °C, in particular may be configured to withstand a temperature from 500 °C to 2000 °C. As outlined above, the layer may be configured as an insulation layer. The insulation layer may be configured for increasing the wall temperature. This can allow for reducing quenching, in particular the recombination of radicals on the wall, etc. As a result, the slip of feedstock can be prevented.

[0052] The layer may be formed from at least one monolithic ceramic or at least one Oxide Ceramic Matrix Composite (OCMC).

[0053] For example, the monolithic ceramic may be at least one material selected from the group consisting of at least one of the following components: a binary oxide (MxOz), a mixed oxide (M1yM2vOz), a metal carbide (M3vCw), a metal nitride (M3vNw), a mixture of binary oxides (M1yOz I M2v0w, MxOz I M1yOz I M2v0w), a mixture of mixed oxides (MxMlyOz I MuM2v0w), a mixure of binary oxide and metal carbides (MxOz I M3vCw) and / or mixtures of binary oxides and metal nitrides (MxOz I M3vNw). O refers to the chemical element oxygen, C to the chemical element carbon and N to the chemical element nitrogen.

[0054] M may be, for example, an element selected from the group consisting of: aluminum (Al), zirconium (Zr), silicon (Si), calcium (Ca), magnesium (Mg), beryllium (Be), yttrium (Y), lanthanum (La), iron (Fe), nickel (Ni), chromium, (Cr), tungsten (W), Hafnium (Hf), strontium (Sr), scandium (Sc), Cer (Ce), ytterbium (Yb).

[0055] Preferably, M may be an element selected from the group consisting of: aluminum (Al), zirconium (Zr), silicon (Si), yttrium (Y), lanthanum (La), Hafnium (Hf), strontium (Sr). More preferably, M may be an element selected from the group consisting of: aluminum (Al), zirconium (Zr), yttrium (Y).

[0056] M1 may be, for example, an element selected from the group consisting of: aluminum (Al), zirconium (Zr), yttrium (Y), magnesium (Mg), silicon (Si). Preferably, M1 may be aluminum. 240327W001

[0057] - 12 -

[0058] M2 may be, for example, an element selected from the group consisting of: zirconium (Zr), silicon (Si), magnesium (Mg), yttrium (Y), titanium (Ti).

[0059] M3 may be, for example, an element selected from the group consisting of: aluminum (Al), silicon (Si), boron (B), tungsten (W). x, y, z, u, v and w may be from 1 to 10 independently of each other, preferably from 1 to 7, and most preferably from 1 to 5.

[0060] For example, the ceramic material may comprise at least one mixture selected from the group consisting of: binary and ternary mixtures of aluminum oxide (AI2O3), zirconium oxide (ZrCh) and yttrium oxide (Y2O3) (e.g. zirconium oxide reinforced aluminum oxide); mixtures of silicon carbide (SiC) and aluminum oxide; mixtures of aluminum oxide and magnesium oxide (MgO spinel); mixtures of aluminum oxide and silicon oxide (mullite); mixture of aluminum silicate and magnesium silicate; ternary mixture of aluminum oxide, silicon oxide and magnesium oxide (cordierite); steatite (magnesium silicate); zirconium oxi de- re info reed aluminum oxide; stabilized zirconium oxide (ZrCh); stabilizers in the form of magnesium oxide (MgO), calcium oxide (CaO) or yttrium oxide (Y2O3), optionally with cerium oxide (CeO2), scandium oxide (ScOs) or ytterbium oxide (YbOs) being used as stabilizers; also aluminum titanate (stoichiometric mixture of aluminum oxide and titanium oxide); silicon nitride and aluminum oxide (silicon-aluminum oxynitrides SIALON).

[0061] As zirconium oxide-reinforced aluminum oxide, it is advantageous to use AI2O3 comprising from 10 to 20 mol % of ZrO2. To stabilize ZrC>2, from 10 to 20 mol% of CaO, preferably 16 mol %, from 10 to 20 mol % of MgO, preferably 16 mol %, or from 5 to 10 mol % of Y2O3, preferably 8 mol % ("fully stabilized zirconium oxide") or from 1 to 5 mol % of Y2O3, preferably 4 mol % ("partially stabilized zirconium oxide") can advantageously be used. An example of an advantageous ternary mixture is 80% of AI2O3, 18.4% of ZrO2 and 1.6% of Y2O3.

[0062] For example, the ceramic material may comprise at last one material selected from the group consisting of: Quartz glass (SiO2), carbon (C), silicon carbide (SiC), silicon nitride (Sisl^ ) , aluminum nitride (AIN), aluminum oxide (AI2O3), zirconium oxide (ZrO2), mullite or fiber composite materials on the basis of these elements.

[0063] For example, the ceramic material may comprise a composite material, e.g. several layers of monolithic ceramic and / or Oxide Ceramic Matrix Composite such as described in WO 2016 / 184776 A1 or EP 3 835 639 A1 . 240327W001

[0064] - 13 -

[0065] The term “composite material” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to an arbitrary material being produced from two or more constituent materials. These constituent materials may have notably dissimilar chemical or physical properties and may be merged to create a material with properties unlike the individual materials. Within the composite material, the individual materials may remain separate and distinct. Specifically, the composite material may be a fiber-reinforced composite material.

[0066] The term “fiber- re info reed composite material (FRC)” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to an arbitrary material generally comprising at least two main components: reinforcing fibers and an embedding matrix which may serve as a filler and / or adhesive between the fibers. Mutual interactions between the two components may give overall material higher-grade properties than either of the two components involved alone. The fiber-reinforced composite (FRC) may specifically comprise the fibers as a discontinuous or dispersed phase, the matrix as a continuous phase and an interphase region, which may also be referred to as interface.

[0067] The term “Ceramic Matrix Composite (CMC)” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to an arbitrary composite material, specifically to an arbitrary fiber-reinforced composite material, comprising a plurality of ceramic fibers embedded in a ceramic matrix. Thereby, carbon and carbon fibers may also be regarded as a ceramic material. The term “Oxide Ceramic Matrix Composite (OCMC)” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to an arbitrary ceramic matrix composite comprising an oxide ceramic matrix reinforced by oxide ceramic reinforcing fibers. The term “OCMC” may refer to pure OCMC structures and to hybrid OCMC structures comprising in addition to the OCMC at least one further material such as metallic fibers. Specifically, OCMCs are fiber reinforced composite materials comprising oxide fibers embedded in a porous matrix of oxide ceramics. Advantages of such OCMCs can be ensuring high temperature resistance up to 1300 °C or above, high thermal shock resistance and quasi-ductile deformation and fracture behavior. An open porosity E of fiber composite ceramics can usually take on values between 5% and 50%. A fracture toughness of OCMC can reach values of KIC = 10 - 50 MPa> / m. As a result 240327W001

[0068] - 14 - of the porous structure, fiber composite ceramics may have a lower density, a lower modulus of elasticity and a lower thermal conductivity coefficient compared to monolithic ceramics with the same chemical composition. The following table gives a list of the relevant standards for the determination of these parameters; in particular a list of relevant norms for the determination of structural, mechanical and thermophysical parameters for monolithic ceramics and for OCMC.

[0069] The thermal conductivity coefficient is defined by the following relationship: thermal conductivity coefficient = density x (specific heat capacity) x thermal diffusivity coefficient.

[0070] As an example, the following table compares between the properties of monolithic ceramics and OCMC based on aluminum oxide.

[0071] For example, the OCMC may be prepared by the following manufacturing procedure: A fiber fabric in the form of a textile or a fiber bundle such as a rovings may be infiltrated with a slurry. The infiltration may be carried out by dipping or knife coating. Several layers may be laminated over a suitable mold until a desired wall thickness is achieved. Drying may be carried out in a temperature range of 40 °C to 150 °C, preferably from 60 °C to 100 °C. In a subsequent step, the OCMC layer may be fired. Firing may take place in a temperature range of 1100 °C to 1300 °C, preferably in a temperature range of 1150 °C to 1250 °C. 240327W001

[0072] - 15 -

[0073] Specifically, components made of OCMs may be manufactured using a manufacturing process as described, for example, in DE102016007652A1 , comprising the following steps: The textile framework is impregnated with a slurry and placed on a mold or laminated. A slurry may be understood to be the pulpy to pasty mixture of water and mineral powder, which is used as a raw mass for the production of ceramic products. For example, the powder contains metal oxides, carbides, nitrides. Preferably, the powder contains aluminum oxide, zirconia, mullite or zirconia reinforced aluminum oxide. Subsequently, the component is dried at temperatures of 40 °C to 150 °C, preferably from 60 °C to 100 °C. This can allow giving the component sufficient stability that it is self-supporting and can be removed from the mold. Finally, the component may be fired in a high-temperature furnace at temperatures of 1100°C to 1300°C, preferably in a temperature range of 1150 °C to 1250 °C. The finished component may comprise an intimate composite of the textile framework and a sintered, porous ceramic matrix. However, also other manufacturing processes may be possible.

[0074] As outlined above, the OCMC may have a matrix, specifically an oxide ceramic matrix. The term “matrix” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to an arbitrary constituent of a composite material. Specifically, the matrix may refer to or may comprise at least one material in which other components are embedded. The matrix may specifically serve the following functions. The matrix may be configured for binding a fiber reinforcement. Further, the matrix may be configured for providing a composite component its shape and may direct its surface quality.

[0075] The matrix may specifically comprise at least one of: a binary oxide (MXOZ); a mixed oxide such as M1xM2yOz and / or M1xM2yM3wOz; a complex matrix comprising a plurality of ceramic particles and / or of metallic particles. Specifically, the OCMC may have a matrix composition selected from the group consisting of: SixMyOz, SixM1yM2wOz, SixByNzCw, AIN, MxOy and mixtures of oxides (M1xOy / M2wOz). For example, the OCMC may have a matrix composition comprising a mixture of oxides such as 85% AI2O3 and 15% ZrO2 (e.g. a matrix available under FW12 from WPS). However, also other kinds of materials may be possible.

[0076] Thereby, O may refer to the chemical element oxygen. B may refer to the chemical element boron (B). N may refer to the chemical element nitrogen (N) and C may refer to the chemical element carbon (C).

[0077] M may specifically be an element selected from the group consisting of: aluminum (Al), zirconium (Zr), silicon (Si), calcium (Ca), magnesium (Mg), beryllium (Be), yttrium (Y), lanthanum (La), iron (Fe), nickel (Ni), chromium (Cr), tungsten (W), hafnium (Hf), strontium (Sr). Preferably, 240327W001

[0078] - 16 -

[0079] M may be an element selected from the group consisting of: aluminum (Al), zirconium (Zr), silicon (Si), strontium (Sr), lanthanum (La), yttrium (Y). M1 may specifically be an element selected from the group consisting of: aluminum (Al), zirconium (Zr), yttrium (Y). Preferably, M1 may be aluminum (Al). M2 may specifically be an element selected from the group consisting of: zirconium (Zr), silicon (Si). Preferably, M2 may silicon (Si). M3 may specifically be cobalt (Co), x, y and w may each independently be between 1 and 10, preferably between 1 and 7 and most preferably between 1 and 5. z may specifically be between 1 and 30, preferably between 1 and 20 and most preferably between 1 and 10.

[0080] Specifically, the matrix may be made of FW12 from Walter E.C. Pritzkow Special Ceramics (85% AI2O3 and 15% 3YSZ).

[0081] The OCMC, specifically the matrix of the OCMC, may have a porosity from 10 % to 60 %, preferably from 20 % to 50 %, more preferably from 20 % to 40%. A pore size of the OCMC, specifically the matrix of the OCMC, may specifically be between 0.001 pm and 100 pm, preferably between 0.01 pm and 10 pm and most preferably between 0.05 pm and 0.5 pm. However, also other embodiments may be possible.

[0082] As outlined above, the OCMC may have a plurality of fibers, specifically a plurality of oxide ceramic reinforcing fibers. The term “fiber” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to an arbitrary element having a length and a width, wherein the length of the element exceeds the width of the element such as at least by a factor of 5, preferably at least by a factor of 10 and most preferably at least by a factor of 20. The fiber may specifically be an artificial fiber. The artificial fiber may be a fiber whose chemical composition, structure, and / or properties may be significantly modified during a manufacturing process. Artificial may refer to regenerated fibers and synthetic fibers.

[0083] The oxide ceramic reinforcing fibers may comprise at least one material selected from the group consisting of: a binary oxide (MXOZ), a mixed oxide (M1xM2yOzor M1xM2yM3wOz), a metal (M), a metal carbide (MxCy). Specifically, OCMC may have oxide ceramic reinforcing fibers comprising at least one material selected from the group consisting of: mullite, AI2O3, a combination of mullite and AI2O3. However, also other kinds of materials may be possible.

[0084] Thereby, O may refer to the chemical element oxygen (O) and C may refer to the chemical element carbon (C). 240327W001

[0085] - 17 -

[0086] M may specifically be an element selected from the group consisting of: aluminum (Al), zirconium (Zr), silicon (Si), calcium (Ca), magnesium (Mg), beryllium (Be), yttrium (Y), lanthanum (La), iron (Fe), nickel (Ni), chromium (Cr), tungsten (W), hafnium (Hf), strontium (Sr),. Preferably, M may be selected from the group consisting of: aluminum (Al), silicon (Si), strontium (Sr), zirconium (Zr), lanthanum (La), yttrium (Y). M1 may specifically be an element selected from the group consisting of: aluminum (Al), zirconium (Zr), yttrium (Y). Preferably, M1 may be aluminum (Al). M2 specifically be an element selected from the group consisting of: silicon (Si), zirconium (Zr). Preferably, M2 may be silicon (Si). M3 may specifically be cobalt (Co), x, y and w may each independently be between 1 and 10, preferably between 1 and 7 and most preferably between 1 and 5. z may specifically be between 1 and 30, preferably between 1 and 20 and most preferably between 1 and 10.

[0087] The OCMC may have a plurality of the oxide ceramic reinforcing fibers which may form a fiber fabric. The term “fiber fabric” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to a manufacturing of the fibers. The fiber fabric may be manufactured in a sheet, a mat, specifically a continuous mat, or as continuous filaments. The fiber fabric may be manufactured from at least one technique selected from the group consisting of: weaving, knitting, braiding and stitching. The fibers may be manufactured in two-dimensional or three-dimensional orientations. In the two-dimensional orientation the fibers may be essentially only aligned along a plane in x-direction, and in y-direction of the material. In the three-dimensional orientation fibers may be incorporated in the x-direction, y-direction and z-direction. The fiber fabric may also be referred to as fiber preform, fiber backbone, fiber scaffold or fiber framework.

[0088] The plurality of the oxide ceramic reinforcing fibers, more specifically the fiber fabric, may have fabric, a mesh, a woven or a knitted structure. However, also other embodiments may be feasible.

[0089] The fiber fabric may specifically be woven in a weave pattern selected from the group consisting of: unidirectional, plain weave, twill K1 / 2, twill K2 / 2, twill K1 / 3, twill 4 / 4, atlas A1 / 4, atlas A1 / 7. Preferred weave patterns may be twill 2 / 2, twill 4 / 4, atlas 1 / 4, atlas 1 / 7, and specifically twill 4 / 4, atlas 1 / 4 and atlas 1 / 7. The fiber fabric may specifically be laminated at an angle of 0 / 90° or at an angle of 45°. However, also other embodiments may be feasible.

[0090] The oxide ceramic reinforcing fibers may have a fiber diameter from 1 pm to 50 pm, preferably from 3 pm to 30 pm and most preferably from 5 pm to 20 pm. However, also other dimensions may be possible. 240327W001

[0091] - 18 -

[0092] A plurality of single oxide ceramic reinforcing fibers, which may also be referred to as filaments, may be bundled to a strand, wire or yarn. Thereby, the plurality of single oxide ceramic reinforcing fibers may essentially extend in one direction. Specifically, the filaments may be twisted into a single yarn strand. One yarn strand may comprise 100 to 20000 filaments, preferably 200 to 10000 filaments. A yarn thickness according to ISO1144 may specifically be in the range of 50 to 2500 Tex, preferably in the range of 100 to 1500 Tex, most preferably in the range of 150 to 1000 Tex. A yarn may specifically be made of 200 to 10000 filaments, preferably of 300 to 3000 filaments, and most preferably of 300 to 2000 filaments. A fiber volume content may specifically be from 5% to 75%, preferably from 10% to 60% and most preferably from 20% to 50%. A diameter of the filaments may be from 1 pm to 50 pm, preferably from 3 pm to 30 pm, more preferably from 5 pm to 20 pm.

[0093] In an exemplary embodiment, a fiber fabric may comprise six superimposed fabric sheets wound in 0 / 90° orientation, e.g. of type DF-11 from 3M (St. Paul, MN, U.S.A.) which may be impregnated with slurry forming the matrix of the OCMC structure after firing. The slurry may comprise a mixture of 85% AI2O3 and 15% ZrC>2. The slurry may comprise additional components.

[0094] For example, the fireroom may be formed from at least one monolithic ceramic or at least one Oxide Ceramic Matrix Composite (OCMC). The term “formed from at least one monolithic ceramic or at least one OCMC” as used herein is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art and is not to be limited to a special or customized meaning. The term specifically may refer, without limitation, to the fact that the material of the walls is at least one monolithic ceramic or at least one OCMC.

[0095] The fireroom may be refractory from -10 °C to 2680 °C, in particular may be configured to withstand a temperature from 500 °C to 2000 C°.

[0096] The reactor may comprise at least one intermediate ring configured for oxygen supply to the fireroom. The intermediate ring may be arranged between the burner block and the fireroom.

[0097] The walls of the fireroom may be water-cooled. The walls, e.g. each of the walls, may comprise an integrated water-cooling, e.g. at least one chamber or at least one channel. The integrated water-cooling may be configured for distributing water at a defined temperature through the walls. 240327W001

[0098] - 19 -

[0099] Reaction temperatures may be in the range of 1500 - 2000°C. A stainless steel fireroom may have problems withstand these temperatures. To enable the use of steel, the fireroom may be equipped with a cooling jacket through which water flows, e.g. as described in WO2012062784. Alternatively, the fireroom may be non-water-cooled. Using a fireroom made from at least one monolithic ceramic or at least one OCMC can allow for using a non-water-cooled fireroom.

[0100] In a further aspect of the invention, a method for manufacturing a reactor according to the present invention such as according one or more embodiments described above or in more details below. With respect to definitions and embodiments of the method, reference can be made to definitions and embodiments of the reactor described above or as described in more details below.

[0101] The method comprises the method steps as given in the corresponding independent claim and as listed as follows. The method steps may be performed in the given order. One or more of the method steps may be performed in parallel and / or in a time overlapping fashion. Further, one or more of the method steps may be performed repeatedly. Further, additional method steps may be present which are not listed.

[0102] The method comprises the following steps: a. providing a mixing unit, a burner block and a fireroom, wherein the mixing unit is configured for mixing feedstock, wherein the feedstock comprises hydrocarbons and oxygen, wherein the burner block and the fireroom are configured for production of hydrocarbons and synthesis gas via partial oxidation, wherein the fireroom has a plurality of walls forming a lateral surface of a hexagonal prism or a truncated hexagonal pyramid; b. manufacturing of the burner block; and c. assembling the mixing unit, the burner block and the fireroom.

[0103] The reactor and method of the present invention have numerous advantages over methods and devices known in the art. The reactor according to the present invention can supersede the application of high-maintenance stoker-robots used for removing coke deposits inside of the reactors required to maintain a continuous acetylene production. Moreover, reduced sound emissions can be reached by adding an additional ring of flow tubes and reduced relative distance between flow tubes.

[0104] As used herein, the terms “have”, “comprise” or “include” or any arbitrary grammatical variations thereof are used in a non-exclusive way. Thus, these terms may both refer to a situation in 240327W001

[0105] - 20 - which, besides the feature introduced by these terms, no further features are present in the entity described in this context and to a situation in which one or more further features are present. As an example, the expressions “A has B”, “A comprises B” and “A includes B” may both refer to a situation in which, besides B, no other element is present in A (i.e. a situation in which A solely and exclusively consists of B) and to a situation in which, besides B, one or more further elements are present in entity A, such as element C, elements C and D or even further elements.

[0106] Further, it shall be noted that the terms “at least one”, “one or more” or similar expressions indicating that a feature or element may be present once or more than once typically are used only once when introducing the respective feature or element. In most cases, when referring to the respective feature or element, the expressions “at least one” or “one or more” are not repeated, nonwithstanding the fact that the respective feature or element may be present once or more than once.

[0107] Further, as used herein, the terms "preferably", "more preferably", "particularly", "more particularly", "specifically", "more specifically" or similar terms are used in conjunction with optional features, without restricting alternative possibilities. Thus, features introduced by these terms are optional features and are not intended to restrict the scope of the claims in any way. The invention may, as the skilled person will recognize, be performed by using alternative features. Similarly, features introduced by "in an embodiment of the invention" or similar expressions are intended to be optional features, without any restriction regarding alternative embodiments of the invention, without any restrictions regarding the scope of the invention and without any restriction regarding the possibility of combining the features introduced in such way with other optional or non-optional features of the invention.

[0108] Summarizing and without excluding further possible embodiments, the following embodiments may be envisaged:

[0109] Embodiment 1 . A reactor configured for production of hydrocarbons and synthesis gas via partial oxidation, comprising a burner block and a fireroom, wherein the fireroom has a plurality of walls forming a lateral surface of a hexagonal prism or a truncated hexagonal pyramid.

[0110] Embodiment 2. The reactor according to the preceding embodiment, wherein the burner block comprises at least one burner flange and at least one burner plate, wherein the burner plate comprises flow tubes, wherein the flow tubes are arranged equally distributed in a 240327W001

[0111] - 21 - hexagonal structure, wherein a distance between the most outer row of flow tubes of the hexagonal structure and the fireroom walls is constant.

[0112] Embodiment 3. The reactor according to the preceding embodiment, wherein the flow tubes have a constant cross sectional area or a varying cross sectional area over the length of the flow tubes.

[0113] Embodiment 4. The reactor according to any one of the two preceding embodiments, wherein each of the flow tubes is designed with a varying cross section over the tube length .

[0114] Embodiment 5. The reactor according to any one of the three preceding embodiments, wherein the distance between the flow tubes is from 42 mm to 36 mm, preferred 38.8 mm.

[0115] Embodiment 6. The reactor according to any one of the four preceding embodiments, wherein the burner plate comprises more than 127, preferably at least 169, flow tubes within the hexagonal structure.

[0116] Embodiment 7. The reactor according to any one of the preceding embodiments, wherein the burner block comprises stainless steel, high-temperature steel stainless steel high-alloyed high-temperature steel (superalloys) such as materials having the following material number 2.4816 (Alloy 600 available from Special Metals Corporation under the brand name Inconel), 2.4663 (Alloy 617), 2.4856 (Alloy 625), 2.4642 (Alloy 690), 2.4668 (Alloy 718), 2.4669 (Alloy X-750), 1.4958 (Alloy 800 H), 2.4973 (Rene 41), 2.4858 (Alloy 825), 2.4654 (Waspalloy), the following materials listed in DIN EN 10095:1999 “Heat resisting steels and nickel alloys” 1.4713, 1.4724, 1.4742, 1.4762, 1.4749, 1.4737 1.4878, 1.4828, 1.4835, 1.4833, 1.4845, 1.4841 , 1.4864, 1.4876, 1.4877, 1.4872, 1.4818, 1.4854, 1.4886, 1.4887, 1.4821 1.4512, 1.4510, 1.4509, 1.4301 , 1.4948, 1.4541 , 1.4941 , 1.4950, 1.4951 , 1.4362, the following materials listed in DIN EN 10028-2:2017 “Flat Products made of steels for pressure purposes - Part 2: Non-alloy and alloy steels with specified elevated temperature properties” 1.0345, 1.0425, 1.0481 , 1.0473, 1.5415, 1.5414, 1.6311 , 1.6368, 1.7335, 1.7336, 1.7380, 1.7375, 1.7362, 1.7703, 1.7767, 1.4903.

[0117] Embodiment 8. The reactor according to any one of the preceding embodiments, wherein the burner block has a cylindrical outer shape.

[0118] Embodiment 9. The reactor according to any one of the preceding embodiments, wherein the walls of the fireroom are metal walls, wherein the metal is stainless steel. 240327W001

[0119] - 22 -

[0120] Embodiment 10. The reactor according to any one of the preceding embodiments, wherein the fireroom is equipped with least one layer at the inside, wherein the layer is formed from at least one monolithic ceramic or at least one Oxide Ceramic Matrix Composite (OCMC).

[0121] Embodiment 11. The reactor according to any one of the preceding embodiments 1 to 7, wherein the fireroom is formed from at least one monolithic ceramic or at least one Oxide Ceramic Matrix Composite (OCMC).

[0122] Embodiment 12. The reactor according to any one of the preceding embodiments, wherein the fireroom comprises at least one intermediate ring configured for oxygen supply to the fireroom, wherein the intermediate ring is arranged between the burner block and the fireroom.

[0123] Embodiment 13. The reactor according to any one of the preceding embodiments, wherein the walls of the fireroom and / or the burner block are water-cooled.

[0124] Embodiment 14. The reactor according to any one of the preceding embodiments, wherein the walls of the fireroom and / or the burner block are non-water-cooled.

[0125] Embodiment 15. A method for manufacturing a reactor according to any one of the preceding embodiments, wherein the method comprises the following steps: a. providing a mixing unit, a burner block and a fireroom, wherein the mixing unit is configured for mixing feedstock, wherein the feedstock comprises hydrocarbons and oxygen, wherein the burner block and the fireroom are configured for production of hydrocarbons and synthesis gas via partial oxidation, wherein the fireroom has a plurality of walls forming a lateral surface of a hexagonal prism or a truncated hexagonal pyramid; b. manufacturing of the burner block; and c. assembling the mixing unit, the burner block and the fireroom.

[0126] Short description of the Figures

[0127] Further optional features and embodiments will be disclosed in more detail in the subsequent description of embodiments, preferably in conjunction with the dependent claims. Therein, the 240327W001

[0128] - 23 - respective optional features may be realized in an isolated fashion as well as in any arbitrary feasible combination, as the skilled person will realize. The scope of the invention is not restricted by the preferred embodiments. The embodiments are schematically depicted in the Figures. Therein, identical reference numbers in these Figures refer to identical or functionally comparable elements.

[0129] In the Figures:

[0130] Figure 1 shows a reactor setup according to the present invention;

[0131] Figures 2a and 2b show an embodiment of a fireroom in cross sectional view and in bottom view; and

[0132] Figure 3 shows a section of an embodiment of a section of burner plate.

[0133] Detailed description of the embodiments

[0134] Figure 1 shows an embodiment of a reactor 100. The reactor comprises a burner block 130 and a fireroom 140. Moreover, an intermediate ring 150 of the reactor 100 between the burner block 130 and the fireroom 140 is depicted. The reactor 100 may further comprise a mixing diffusor 160, also denoted as mixing unit, and a quench body 170, also denoted as quench unit. The reactor 100 is configured for production of hydrocarbons and synthesis gas via partial oxidation. With respect to the production of hydrocarbons and synthesis gas via partial oxidation reference is made to DE 875198, DE 1051845, DE1057094 and DE 4422815. The reactor 100 may be a part of a partial oxidation acetylene plant. The reactor 100 may be reactor system comprising a plurality of units such as mixing unit 160, the burner block 130, the fireroom 140, and a quench unit 170. The mixing unit and / or the quench unit may be designed as described in Ullmanns Encyclopedia of Industrial Chemistry, Passler, P., Hefner, W., Buckl, K., Meinass, H., Meiswinkel, A., Wernicke, H.-J., Ebersberg, G., Muller, R., Bassler, J., Behringer, H. and Mayer, D. (2011), Acetylene, pages 287-293.

[0135] The burner block 130 may comprise at least one burner plate 114 and at least one burner flange 116, as shown e.g. in Figure 3. The burner flange 116 may be configured for holding and / or positioning the burner plate 114. For example, the burner flange 116 may be used for clamping the burner block 130 between a mixing unit and a quench unit of the reactor. 240327W001

[0136] - 24 -

[0137] The burner block 130, in particular the burner plate 114 and / or the burner flange 116, may comprise stainless steel, high-temperature steel stainless steel high-alloyed high-temperature steel (superalloys) such as materials having the following material number 2.4816 (Alloy 600 available from Special Metals Corporation under the brand name Inconel), 2.4663 (Alloy 617), 2.4856 (Alloy 625), 2.4642 (Alloy 690), 2.4668 (Alloy 718), 2.4669 (Alloy X-750), 1.4958 (Alloy 800 H), 2.4973 (Rene 41), 2.4858 (Alloy 825), 2.4654 (Waspalloy), the following materials listed in DIN EN 10095:1999 “Heat resisting steels and nickel alloys” 1.4713, 1.4724, 1.4742, 1.4762, 1.4749, 1.4737 1.4878, 1.4828, 1.4835, 1.4833, 1.4845, 1.4841, 1.4864, 1.4876, 1.4877, 1.4872, 1.4818, 1.4854, 1.4886, 1.4887, 1.4821 1.4512, 1.4510, 1.4509, 1.4301 , 1.4948, 1.4541, 1.4941, 1.4950, 1.4951 , 1.4362, the following materials listed in DIN EN 10028-2:2017 “Flat Products made of steels for pressure purposes - Part 2: Non-alloy and alloy steels with specified elevated temperature properties” 1.0345, 1.0425, 1.0481, 1.0473, 1.5415, 1.5414, 1.6311, 1.6368, 1.7335, 1.7336, 1.7380, 1.7375, 1.7362, 1.7703, 1.7767, 1.4903.

[0138] The burner block 130 may comprise an optional refractory layer 124 which is arranged on top of the burner plate and an optional cover plate 112 which is arranged on top of the refractory layer 124. The refractory layer 124 may be configured for thermal decoupling of the system.

[0139] Figures 2a and 2b show an embodiment of a fireroom in cross sectional view and in bottom view. In the bottom view, the bottom of the burner block 130 is visible. Figure 3 shows a section of the embodiment shown in Figure 2b. In particular, Figure 3 is a sectional drawing along A to A of the burner block 130, where an exemplary area of the burner block 130, in particular of the burner plate 114, is enlarged.

[0140] The burner plate 114 may comprise a plurality of flow tubes 110. The burner block may be arranged between the mixing unit and the fireroom 140. In particular, one end of the flow tube 110 may be arranged facing the mixing unit and the other end of the flow tube 110 may be arranged facing the fireroom 140. The burner block 130 may be configured such that the pre-heated and mixed raw materials flow through the flow tubes 110 from the mixing unit to the fireroom 140.

[0141] The flow tubes 110 may be arranged equally distributed in a hexagonal structure. The hexagonal structure may be a hexagonal shape of an outer contour of the arrangement flow tubes in a bottom view on the burner plate, e.g. as shown in Figure 2b. In a bottom view on the burner plate, such as shown in Figure 2b, the hexagonal structure may have a hexagonal outer contour. The flow tubes 110 within the hexagonal structure may be arranged concentrically on hexagonal rows around a center of the burner block 130. A single flow tube 110 may be arranged at 240327W001

[0142] - 25 - the center of the burner block 130. The burner plate 114 may comprise more than 127, preferably at least 169, flow tubes 110 within the hexagonal structure. The distance between the flow tubes 110, i.e. a relative distance between two flow tubes 110, may be from 42 mm to 36 mm, preferred 38.8 mm. A distance between the most outer row of flow tubes 110 of the hexagonal structure and the fireroom walls may be constant. It was found that sound emission of the reactor 110 is strongly depending on reactor capacity and thereby gas flow velocity inside of the flow tubes. By lowering the distance between the tubes < 42 mm, on the one hand and adding an additional ring of tubes compared to known burner blocks on the other hand for maintaining the overall geometry of the burner block, the gas flow velocity inside the flow tubes 110 can be reduced by approx. 20%.

[0143] For example, the flow tubes 110 have a constant cross sectional area. The cross sectional area may be defined as area perpendicular to a center line of the flow tube 110. The burner block may have a number of continuous channels. Alternatively, the flow tubes 110 may have a varying cross sectional area over the length of the flow tubes 110. Each of the flow tubes 110 may be designed with a varying cross section over the tube length. For example, the flow tube may have at least one geometry selected from the group consisting of: a widening of the cross sectional area over the length of the flow tube, e.g. from one end of the flow tube, e.g. the end facing the mixing unit, to the other end, e.g. facing the fireroom; a widening of the cross sectional area over parts of the length of the flow tube; a Venturi pipe, a diffusor; and the like.

[0144] The burner block 130 may comprise openings 122, e.g. as shown in Figure 2b, facing the fireroom 140 through which a purge medium, e.g. additional oxygen, denoted as auxiliary oxygen, may be fed into the reaction mixture. Any purge medium may be useful, preferably oxygen. The temperatures of the purge medium are preferably below 600° C, more preferably within a range from 200 to 500° C. In this context, the temperatures mentioned relate to the entrance temperature of the purge medium into the fireroom 140. At these openings 122 flames can form and initiate the flame reaction. With respect to means for flame reaction reference is made to WO 2012 / 065284. The openings 122 may be arranged between the flow tubes 110. The burner block 130 may comprise at least one oxygen chamber 118, such as an annular space, and a connected volume for distributing the auxiliary oxygen to the openings 122, in particular in an evenly distributed manner. The openings 122 may be designed as described in WO 2012 / 062584, e.g. Figures 1 and 2. The openings 122 may have a circular cross section, but it is also possible to employ other geometries. The number of openings 122 in relation to an area segment being considered preferably exceeds the number of flow tubes 110. For example, large proportions of the purge gas added are conducted parallel to the surface on the fireroom 240327W001

[0145] - 26 -

[0146] 140 side of the burner block. An advisable proportion here is from 20 to 100% by volume, particularly 70 to 100% by volume. It may be particularly advisable here that the purge gas stream exiting from the distributor device is distributed radially in relation to the center axis of the feed line by a multitude of orifices arranged, preferably homogeneously, over the outer circumference of a distributor, which ensures a homogeneous (preferably parallel) distribution of the purge gas over the surface on the fireroom 140 side of the burner block.

[0147] The auxiliary oxygen may be fed radially into the oxygen chamber 118 and distributed into the volume. The arrangement of the distribution ring to the oxygen chamber 118 and connected volume may be designed as described in WO 2015 / 028539 as annular space and secondary space.

[0148] The reactor may comprise a further distribution ring, in particular intermediate ring 150 arranged between the burner block 130 and the fireroom 140. The intermediate ring 150 may be configured for radially providing oxygen to the fireroom 140. The intermediate ring 150 can allow providing oxygen to edge areas, in which openings 122 may not be present.

[0149] Generally, the radial and axial distribution of oxygen may be designed as described in WO 2012 / 062584, e.g. Figure 2.

[0150] The burner block 130 may be water-cooled. The burner block 130 may comprise a water-cooled burner plate, e.g. a water-cooled steel plate. The burner block 130 may comprise an integrated water-cooling. The integrated water-cooling may comprise at least one water-cooling chamber 120. The water-cooling chamber 120 may be configured for distributing water at a defined temperature through the burner block 130, e.g. as described in Ullmanns Encyclopedia of Industrial Chemistry, Passler, P., Hefner, W., Buckl, K., Meinass, H., Meiswinkel, A., Wernicke, H.-J., Ebersberg, G., Muller, R., Bassler, J., Behringer, H. and Mayer, D. (2011), Acetylene, pages 287-293. Alternatively, the burner block 130 may be non-water-cooled.

[0151] As shown, e.g. in Figure 2a, the fireroom 140 may have a plurality of walls. The walls of the fireroom 140 may form a space or volume in which the exothermic direction can take place. The walls of the fireroom may delimit the fireroom 140. The fireroom has a plurality of walls forming a lateral surface of a hexagonal prism or a truncated hexagonal pyramid. Figure 2A shows an embodiment of a hexagonal prism. The fireroom further may comprise edge walls or connecting walls configured for connecting the walls forming the side faces. Thus, in comparison to known reactor designs, the present invention proposes redesigning the fireroom 140. Instead of a circular basic shape a hexagon can be used. With this approach the distance between the outer 240327W001

[0152] - 27 - ring of flow tubes of the burner block 130 and the wall of the fireroom 140 is constant and minimized. This can allow minimizing hot gas recirculation zones close to the walls of the fireroom 140 in which the coke is formed and can prevent coke deposits on the fireroom walls as well. The decreased distance between the flames and wall of the fireroom 140 may increase the heat transfer from the flame to the wall, which e.g. is water-cooled, and therefore quenches the reaction and acetylene formation in this area. To reduce the quenching a layer 148, in particular configured as an insulation layer, may be added to the fireroom to increase the wall temperature for reducing quenching. The hexagonal fireroom, in particular in combination of an oxygenflushed burner block surface, can enable a stable operation of the acetylene reactors without stoker robots.

[0153] For example, the walls of the fireroom 140 may be metal walls. The metal may be stainless steel.

[0154] For example, the fireroom 140 may be equipped with the at least one layer 148 at the inside. The layer 148 may be a cover and / or coating and / or sheet and may cover the surface of the walls facing the space where the exothermic reaction can take place. The layer 148 may be formed from at least one monolithic ceramic or at least one Oxide Ceramic Matrix Composite (OCMC). The layer 148 may be a ceramic insulation layer.

[0155] The layer 148 at the inside may be refractory from -10 °C to 2680 °C, in particular may be configured to withstand a temperature from 500 °C to 2000 C°. As outlined above, the layer 148 may be configured as an insulation layer. The insulation layer may be configured for increasing the wall temperature. This can allow for reducing quenching.

[0156] For example, the fireroom 140 may be formed from at least one monolithic ceramic or at least one Oxide Ceramic Matrix Composite (OCMC). In particular the material of the walls may be at least one monolithic ceramic or at least one OCMC.

[0157] The fireroom may be refractory from -10 °C to 2680 °C, in particular may be configured to withstand a temperature from 500 °C to 2000 C°.

[0158] The walls of the fireroom may be water-cooled. Each wall of the fireroom 140 may comprise an outer fireroom wall 142 and an inner fireroom wall 144. Between the outer fireroom wall 142 and the inner fireroom wall 144 a water-cooling annulus 146 may be arranged. The water-cooling annulus 146 may be configured for distributing water at a defined temperature through the walls. Alternatively, the fireroom may be non-water-cooled. 240327W001

[0159] - 28 -

[0160] List of reference numbers

[0161] 100 reactor

[0162] 110 flow tubes

[0163] 112 cover plate

[0164] 114 burner plate

[0165] 116 burner flange

[0166] 118 oxygen chamber

[0167] 120 water-cooling chamber

[0168] 122 opening

[0169] 124 refractory

[0170] 130 burner block

[0171] 140 fireroom

[0172] 142 outer fireroom wall

[0173] 144 inner fireroom wall

[0174] 146 water cooling annulus

[0175] 148 layer

[0176] 150 intermediate ring

[0177] 160 mixing diffusor

[0178] 170 quench body

Claims

240327W001- 29 -Claims1 . A reactor (100) configured for production of hydrocarbons and synthesis gas via partial oxidation, comprising a burner block (130) and a fireroom (140), wherein the fireroom (140) has a plurality of walls forming a lateral surface of a hexagonal prism or a truncated hexagonal pyramid.

2. The reactor (100) according to the preceding claim, wherein the burner block (130) comprises at least one burner flange (116) and at least one burner plate (114), wherein the burner plate (114) comprises flow tubes (110), wherein the flow tubes (110) are arranged equally distributed in a hexagonal structure, wherein a distance between the most outer row of flow tubes (110) of the hexagonal structure and the fireroom walls is constant.

3. The reactor (100) according to the preceding claim, wherein the flow tubes (110) have a constant cross sectional area or a varying cross sectional area over the length of the flow tubes (110).

4. The reactor (100) according to any one of the two preceding claims, wherein each of the flow tubes (110) is designed with a varying cross section over the tube length.

5. The reactor (100) according to any one of the three preceding claims, wherein the distance between the flow tubes (110) is from 42 mm to 36 mm, preferred 38.8 mm.

6. The reactor (100) according to any one of the four preceding claims, wherein the burner plate (114) comprises more than 127, preferably at least 169, flow tubes (110) within the hexagonal structure.

7. The reactor (100) according to any one of the preceding claims, wherein the burner block (130) comprises stainless steel, high-temperature steel stainless steel high-alloyed high- temperature steel (superalloys) such as materials having the following material number 2.4816 (Alloy 600 available from Special Metals Corporation under the brand name Inconel), 2.4663 (Alloy 617), 2.4856 (Alloy 625), 2.4642 (Alloy 690), 2.4668 (Alloy 718), 2.4669 (Alloy X-750), 1.4958 (Alloy 800 H), 2.4973 (Rene 41), 2.4858 (Alloy 825), 2.4654 (Waspalloy), the following materials listed in DIN EN 10095:1999 “Heat resisting steels and nickel alloys” 1.4713, 1.4724, 1.4742, 1.4762, 1.4749, 1.4737 1.4878, 1.4828, 1.4835, 1.4833, 1.4845, 1.4841 , 1.4864, 1.4876, 1.4877, 1.4872, 1.4818, 1.4854, 1.4886, 1.4887, 1.4821 1.4512, 1.4510, 1.4509, 1.4301 , 1.4948, 1.4541 , 1.4941 , 1.4950, 1.4951 , 1.4362,240327W001- 30 - the following materials listed in DIN EN 10028-2:2017 “Flat Products made of steels for pressure purposes - Part 2: Non-alloy and alloy steels with specified elevated temperature properties” 1.0345, 1.0425, 1.0481 , 1.0473, 1.5415, 1.5414, 1.6311 , 1.6368, 1.7335, 1.7336, 1.7380, 1.7375, 1.7362, 1.7703, 1.7767, 1.4903.

8. The reactor (100) according to any one of the preceding claims, wherein the burner block (130) has a cylindrical outer shape.

9. The reactor (100) according to any one of the preceding claims, wherein the walls of the fireroom (140) are metal walls, wherein the metal is stainless steel.

10. The reactor (100) according to any one of the preceding claims, wherein the fireroom (140) is equipped with least one layer (148) at an inside, wherein the layer (148) is formed from at least one monolithic ceramic or at least one Oxide Ceramic Matrix Composite (OCMC).11 . The reactor (100) according to any one of the preceding claims 1 to 7, wherein the fireroom (140) is formed from at least one monolithic ceramic or at least one Oxide Ceramic Matrix Composite (OCMC).

12. The reactor (100) according to any one of the preceding claims, wherein the fireroom (140) comprises at least one intermediate ring (150) configured for oxygen supply to the fireroom (140), wherein the intermediate ring (150) is arranged between the burner block (130) and the fireroom (140).

13. The reactor (100) according to any one of the preceding claims, wherein the walls of the fireroom (140) and / or the burner block (130) are water-cooled.

14. The reactor (100) according to any one of the preceding claims, wherein the walls of the fireroom (140) and / or the burner block (130) are non-water-cooled.

15. The reactor (100) according to any one of the preceding claims, wherein a reaction mixture after flowing through the burner block (130) enters the fireroom (140) and is brought to an exothermic reaction within the fireroom (140).

16. A method for manufacturing a reactor (100) according to any one of the preceding claims, wherein the method comprises the following steps:240327W001- 31 - a. providing a mixing unit, a burner block (130) and a fireroom (140), wherein the mixing unit is configured for mixing feedstock, wherein the feedstock comprises hydrocarbons and oxygen, wherein the burner block (130) and the fireroom (140) are configured for production of hydrocarbons and synthesis gas via partial oxidation, wherein the fireroom (140) has a plurality of walls forming a lateral surface of a hexagonal prism or a truncated hexagonal pyramid; b. manufacturing of the burner block (130); and c. assembling the mixing unit, the burner block (130) and the fireroom (140).

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