Shell-and-tube reactor for natural gas reforming
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Solution Overview
Problem
Conventional natural gas reforming processes for producing syngas and hydrogen are inefficient and economically unfeasible due to high operating temperatures and the need for separate reactors, which limits the production of high-purity hydrogen and carbon dioxide collection.
Innovation Solution
A shell-and-tube reactor design that incorporates a reaction catalyst for natural gas reforming, a tube for hydrogen separation, and a tube-type heat-exchanger or exothermic reaction tube at its center, allowing simultaneous hydrogen production and carbon dioxide collection, enabling operation at lower temperatures and reducing the complexity of subsequent purification processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional steam methane reforming is used, then syngas production is achieved, but high operating temperature (700-900°C) is required leading to low operating efficiency and high cost
Solution Approach 1:
The patent combines the endothermic steam methane reforming reaction and the exothermic combustion reaction into a single reactor system. The heat generated from the exothermic combustion of part of the natural gas provides the necessary heat for the endothermic reforming reaction, eliminating the need for external high-temperature heating and enabling operation at lower temperatures with improved efficiency.
Solution Approach 2:
The patent converts the harmful effect of requiring high external heat input (which reduces operating efficiency) into a beneficial self-heating system. By combusting part of the natural gas feedstock within the reactor, the system generates its own heat, turning what would be a waste stream into the heat source needed for reforming, thereby improving overall operating efficiency.
2Device complexity
If separate reactors are used for reforming and purification, then complete processing is achieved, but device complexity increases and compact design becomes difficult
Solution Approach 1:
The patent integrates multiple functions including reforming, partial oxidation, and carbon dioxide separation into a single shell-and-tube reactor system. The shell side accommodates the reforming catalyst while the tube side enables CO2 separation, allowing complete processing within one reactor and reducing overall device complexity.
Solution Approach 2:
The reactor is designed to perform multiple functions simultaneously: steam methane reforming, partial oxidation of natural gas, and carbon dioxide separation. This multi-functional design eliminates the need for separate reactors for each process step, achieving compact configuration without compromising process completeness.
3Productivity
If high-purity hydrogen production is pursued, then subsequent purification processes are required, but process complexity and cost increase
Solution Approach 1:
The patent performs preliminary carbon dioxide separation during the reforming process itself using the tube-side separation functionality. By removing CO2 at the source before the gas leaves the reactor, the system pre-purifies the syngas, reducing the burden on subsequent purification processes and maintaining high hydrogen production efficiency.
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 high-purity hydrogen production and carbon dioxide collection efficiently, lowering production costs by 20-30% and enabling compact, economically viable clean energy production with reduced carbon dioxide emissions.
Implementation Method 1
a tube for an exothermic reaction or a tube type heat-exchanger for heating, which is disposed at the center of the reactor
Implementation Method 2
a reaction catalyst for reforming natural gas, which is filled in a reactor shell
Implementation Method 3
at least one tube for separating hydrogen
Data Source
AI summary
The present invention relates to a shell-and-tube type reactor for reforming natural gas and a method for manufacturing syngas or hydrogen gas by using the same. According to the present invention, a shell-and-tube type reactor for reforming natural gas comprises a reaction catalyst for reforming natural gas, which is filled in a reactor shell; at least one tube for separating hydrogen; and a tube for an exothermic reaction or a tube type heat-exchanger for heating, which is disposed at the center of the reactor so as to have excellent operating efficiency and enable production of high-purity hydrogen and collection of carbon dioxide simultaneously along with a reaction.