Micro-channel Reactor Porous Nickel Plate Catalyst Heat Control
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Solution Overview
Problem
Current micro-channel reactors face challenges in efficiently controlling reaction heat during the methanation process for producing synthetic natural gas, leading to catalyst activity deterioration due to thermal conductivity issues with ceramic-supported catalysts.
Innovation Solution
A micro-channel reactor design incorporating a porous nickel plate catalyst with integrated upper and lower heat exchangers and gas distributors for enhanced heat transfer and uniform gas distribution, minimizing heat generation and maintaining catalyst activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ceramic-supported nickel catalyst is used in a conventional reactor, then the catalyst provides good catalytic activity for methanation, but the low thermal conductivity of the ceramic support causes temperature increase and catalyst sintering
Solution Approach 1:
The patent employs a porous nickel plate catalyst where nickel is deposited on a porous metal plate structure. The porous structure provides high surface area for catalytic activity while the metal plate substrate provides superior thermal conductivity compared to ceramic supports, enabling efficient heat dissipation and preventing catalyst sintering during the highly exothermic methanation reaction.
Solution Approach 2:
The catalyst system combines nickel metal particles deposited on a porous metal plate support, creating a composite structure that integrates the catalytic properties of nickel with the thermal management properties of the metal substrate. This composite approach resolves the contradiction between maintaining catalyst activity and controlling temperature.
2Productivity
If the methanation reaction is performed in a conventional reactor, then the reaction proceeds with high conversion rate, but the exothermic reaction causes rapid temperature increase that deteriorates catalyst performance
Solution Approach 1:
The patent converts the harmful effect of exothermic reaction heat into a beneficial feature by using the porous nickel plate's high thermal conductivity to rapidly conduct away reaction heat. The heat generated by the high-rate methanation reaction is efficiently dissipated through the metal plate structure, preventing temperature runaway while maintaining high conversion rates.
Solution Approach 2:
The invention changes the thermal parameter of the catalyst support from low thermal conductivity (ceramic) to high thermal conductivity (metal), fundamentally altering the heat management characteristics of the reactor and enabling high-rate operation without temperature deterioration.
3Temperature
If a porous nickel plate catalyst is used to improve heat control, then thermal management is enhanced, but the reactor design becomes more complex
Solution Approach 1:
The porous nickel plate catalyst serves multiple functions simultaneously: it provides catalytic activity for methanation, acts as a heat conduction pathway for thermal management, and serves as the structural support for the catalyst layer. This multi-functionality reduces the need for separate heat management components, simplifying the overall reactor design despite the advanced functionality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The reactor achieves efficient heat control and maintains catalyst activity, ensuring high methanation reaction efficiency and commercial viability by uniformly distributing reaction heat and preventing temperature increases.
Implementation Method 1
converted into methane under a catalyst having Ni supported on a ceramic support as a main component
Implementation Method 2
the methanation reaction (3H2+CO→CH4+H2O) is a very strong exothermic reaction (having reaction heat of 206.1 kJ/mol)
Implementation Method 3
upper and lower heat exchangers each provided between the upper and lower plates
Implementation Method 4
a porous nickel plate catalyst part... in order to more efficiently control reaction heat
Data Source
AI summary
The present invention relates to a micro-channel reactor for producing synthetic natural gas, and more particularly, to a micro-channel reactor for producing synthetic natural gas containing methane gas from synthetic gas, including a porous nickel plate catalyst part.