CN219942764U

CN219942764U - Reactor for synthesizing methanol or other products

Info

Publication number: CN219942764U
Application number: CN202321635903.8U
Authority: CN
Inventors: I·M·琼森; E·萨伦
Original assignee: Carbon Recovery International
Current assignee: Carbon Recovery International
Priority date: 2023-04-14
Filing date: 2023-06-26
Publication date: 2023-11-03
Anticipated expiration: 2033-06-26
Also published as: CN220091336U

Abstract

The utility model discloses a reactor, comprising: a housing defining an interior space configured to receive a catalyst; at least one inlet nozzle; and a tube bundle comprising a plurality of tubes arranged in concentric bands about a longitudinal axis of the reactor. Wherein the reactor further comprises a catalyst support plate comprising a plurality of openings formed therethrough, a plurality of tubes of the tube bundle extending therethrough, a support ring being connected around each tube extending through a respective opening of the catalyst support plate, the tubes being unfixed relative to the catalyst support plate to permit thermal expansion of the tubes extending through the catalyst support plate.

Description

Reactor for synthesizing methanol or other products

Cross Reference to Related Applications

The present utility model is a continuation-in-part application of U.S. application Ser. No. 17/574,992, filed on 1 month 13 of 2022, which claims priority from U.S. provisional application Ser. No. 63/138,022 filed on 1 month 15 of 2021. The entire contents of all of the above applications are incorporated herein by reference.

Technical Field

The present disclosure relates to reactors, particularly reactors for methanol synthesis.

Background

Global climate change has been considered as the "most urgent environmental challenge in the present time". The National Aviation Space Agency (NASA) states that: the scientific evidence of the warming of the climate system is clear. Climate change is caused by the warming effect of the chamber gases such as water vapor, nitrous oxide, methane and carbon dioxide. Among them, carbon dioxide emissions are critical culprit, since the carbon dioxide concentration in the global atmosphere has increased by one third since the beginning of the industrial revolution. Carbon dioxide emissions are mainly derived from human activities such as the consumption of fossil fuels, the by-products of which are emitted into the atmosphere.

Chemical energy storage has been explored as a solution to the intermittent and unpredictable problems inherent in renewable energy sources such as wind and solar energy. Because of the intermittence of wind and solar energy, grids and power companies must meet basic power demands by fossil fuel-based energy sources, and because of the difficulty in rapidly shrinking and expanding the scale of such fossil fuel-based energy sources (e.g., coal-fired power plants), the sudden onset of wind and solar energy is difficult to incorporate into the grid. Since many renewable energy sources are difficult to scale up to replace traditional fossil fuel energy sources, it is critical to handle climate change to store energy in high density from renewable energy sources so that renewable energy sources can be stored and used when the grid can accommodate these energy sources.

To date, existing energy storage means, including thermal energy storage, compressed air energy storage, hydrogen energy storage, pumped storage and large scale batteries have proven to be very expensive and/or difficult to scale up. Chemical storage of renewable energy in the form of hydrogen produced by electrolysis of water, such as for combustion, fuel cell consumption, or chemical synthesis (e.g., methanol synthesis), is a promising approach to provide sufficiently dense and stable renewable energy storage that can be used when needed, such that renewable energy continues to supply energy demand rather than intermittently.

The reactors used for synthesizing methanol from synthesis gas are generally limited to Boiling Water Reactors (BWRs) because of the high heat of typical reaction packages, which include large amounts of CO. BWRs are complex and expensive devices, but are often necessary to reduce the heat generated during the exothermic process of producing methanol from synthesis gas, thereby protecting the reaction products, reactors and catalysts.

Shell-and-tube reactors for catalytic and/or exothermic reactions (e.g., synthesis of methanol from carbon dioxide and hydrogen using suitable catalysts, such as copper and zinc oxide based catalysts or other suitable catalysts) must be subjected to periodic maintenance, such as loading and/or removal and refilling of catalyst, descaling of reactor shells, repair of various components, or other operations. There is a need to balance the ability to access the interior of the reactor for catalyst loading, maintenance and other purposes with maintaining the tubes in bundles.

Existing shell-and-tube reactor designs are difficult to scale up or down depending on the needs of a particular facility (e.g., the desired throughput). The production of the facility may change over time due to the de-bottleneck operation, which may increase the reactor production requirements. Scaling up the reactor to eliminate the facility bottlenecks is a difficult, expensive and time consuming task, and in many cases the entire reactor (including the internal structure) needs to be modified or redesigned.

This can require significant design and engineering effort, as engineers must essentially "subvert" the design into scale, taking into account the arrangement and cross-sectional area of the tubes, the size and configuration of the housing, the volume and cross-sectional area of the catalyst bed, and other things. It is difficult for both existing shell-and-tube reactor designs and suppliers to adapt the reactor design in an efficient manner to changing requirements. If the reactor is improperly designed, maldistribution of catalyst, reactants, and heat may result, damaging the catalyst and/or reactor components and reducing the efficiency of the reaction. In some cases, uncontrolled exothermic reactions may lead to catastrophic failure of the reactor.

Furthermore, it is difficult to properly manufacture and scale feed tubes in and/or for the reactor. Improperly designed, placed, and/or manufactured feed tubes often result in blockage, swirling, and uneven areas of reactants within the reactor, which adversely reduces the efficiency and yield of the reactor and may create hot spots. Hot spots in exothermic reactions are particularly dangerous and detrimental to the reactor and catalyst.

Another problem in reactor design is the difficulty in measuring the reactor internal temperature at one or more desired locations. Without knowing the temperature profile inside the reactor, in particular the temperature profile at different positions along the reactor body corresponding to different phases of the reaction and/or different reaction conditions, it is difficult to control the process including the reactor correctly, in particular in high risk applications such as exothermic reactions.

However, the thermocouple junctions, including the gasket seat, may be damaged over time, resulting in leakage of the thermocouple junctions. While this leak can be repaired, doing so requires the catalyst to be deactivated and the gasket seat to be replaced. This involves expensive, potentially dangerous and time consuming shut down, catalyst deactivation and start up, each of which requires high costs, including significant opportunity costs. Such repairs constitute a very expensive interruption in the operation of the facility, considering that the expected service life of the catalyst is typically between three and five years. Furthermore, in high pressure and/or high temperature reactions involving hydrogen, the risk of leakage from the flanged joint is particularly high, including outward leakage of hydrogen or other reactants/products, and inward leakage of catalyst poisons, i.e., oxygen.

Thus, existing reactor designs include multiple thermocouple wells for providing thermocouples at different height locations of the reactor body that are prone to operational disruption due to thermocouple junction leakage, while omitting a reactor design of such thermocouple wells to avoid disruption lacks the necessary reactor condition data to properly control the reaction. Furthermore, existing thermocouple well arrangements in the reactor insert thermocouples into the reactor body transversely to the flow direction (e.g. radially). This can disadvantageously result in temperature readings for large reactors approaching the conditions of the enclosure, which further makes expansion of the reactor design difficult. The reactor design also makes it difficult to allow the thermocouple to be inserted into the reactor body in the presence of the catalyst without damaging the thermocouple.

Existing reactor designs may include one or more nozzles for unloading spent catalyst, such as from the bottom of the reactor body. The construction of the catalyst unloading nozzles of existing reactors is not suitable for efficient and rapid removal of catalyst, and thus the operator must scrape the catalyst from the reactor body.

Some shell-and-tube reactors and other types of reactors may include an inlet nozzle from which reactant gases are withdrawn through a tube extending through the center of the reactor body. The tube may be drilled to fit one or more feed tubes, each of which may be bent to connect to the tube and then deliver the reactants upwardly through the reactor body. Such a reactor configuration is not suitable for scale-up, for example to several hundred tubes, because precise and specific adjustments to the tubes must be made in order to connect the tubes to each feed tube.

The inlet tube in some reactor configurations is further used to support the feed tube at different heights within the reactor body, with one or more flat strips welded and extending between the inlet tube and the feed tube or tubes. This construction is very time consuming, especially for manufacturing, assembling and maintaining large reactors, which complicates the task of expanding the reactor design according to the requirements of the installation. Furthermore, the inlet tube disadvantageously occupies a large cross-sectional area which would otherwise be occupied by the catalyst. While tie rods have been considered to support the feed tubes in a shell-and-tube reactor, such support can take up catalyst space and can create an obstacle during catalyst loading and unloading.

As described above, there is a need for an improved reactor configured to maintain the reactor interior and manage catalyst, increase or decrease reactor throughput based on facility throughput requirements, improve measurements of reactor conditions without affecting reactor integrity and maintainability, effectively remove spent catalyst, improve manufacturing, and overcome challenges in building shell-and-tube reactors.

Disclosure of Invention

Embodiments of the reactor according to the present disclosure advantageously address the shortcomings of existing reactor designs by providing a reactor that is expandable and/or configured to improve accessibility and maintainability of the reactor (particularly the interior of the reactor). Embodiments of the reactor may be configured to facilitate access to the interior of the reactor without sacrificing strength and robustness of the reactor internal components, such as a reactor tube bundle comprised of one or more tubes and one or more support structures, so that the tube bundle remains intact and undamaged.

Embodiments of the reactor further include a tube arrangement configured to easily scale up or down depending on the needs of a particular facility. While in existing reactor designs, tubes cannot be easily added to or removed from the tube bundle in the shape of the reactor shell without significant redesign work in constructing the reactor, embodiments of the present disclosure advantageously allow for modular placement of circumferential bands or other arrangements of tubes according to the desired throughput of the reactor and associated facilities. In some embodiments, the arrangement of tubes may define a regular and/or repeating pattern that may be simply added to and/or removed from an existing tube bundle design when designing the reactor. This has the advantage of making the debottlenecking operation or other design effort easier and less costly from a manufacturing point of view.

The arrangement of the tube bundles further promotes the distribution of heat and reactants throughout the reactor interior, particularly through the catalyst bed, without disrupting catalyst loading, which typically occurs when an operator loads or dumps catalyst particles from the open top end of the reactor into the reactor interior. The arrangement of the reactor and tube bundle of the embodiments of the present utility model advantageously provides a modular design to improve constructability while maintaining desirable characteristics regarding heat and reactant distribution, and also ensures uniform distribution of catalyst particles inside the reactor.

The tube bundles according to embodiments of the present disclosure are further configured to provide improved structural support to one or more tubes to increase the robustness of the reactor during construction, transport, and installation, as well as during operation. In some embodiments, one or more structural supports and/or one or more tubes are provided in an increased thickness to ensure structural support at the desired location of the tube bundle.

In some embodiments, the reactor and its components are configured to facilitate accessibility for critical component repair. One or more plates configured to support the tube bundle may be modular so that an operator can easily load and unload catalyst or access components inside the reactor, as opposed to prior art reactors where components such as support plates were welded to the inner surface of the reactor shell, prohibiting access to the components inside the reactor.

By providing improved inlet nozzles and distribution mechanisms configured to direct reactants into a tube bundle disposed inside the reactor, embodiments of the reactor solve the problem of existing reactor designs not being suitable for providing proper flow and reactant distribution and thus heat distribution within the reactor and catalyst bed. In some embodiments, the inlet nozzle is positioned adjacent to the gas inlet plate with a flow direction opposite to the flow direction of the tubes in the tube bundle. A second inlet nozzle may be provided at the bottom of the reactor, which may be configured with structure for evenly distributing the fluid into the tubes of the tube bundle. In some embodiments, one or more catalyst unloading nozzles are provided in a modified configuration for catalyst removal, the unloading nozzles being configured to have a downward angle.

The arrangement of the tube bundles and the tubes allows the cross-sectional area of the tubes to be improved relative to the cross-sectional area of the catalyst to achieve uniform heat and flow distribution without interfering with the structural and modular features of the tube bundles.

Embodiments of the reactor are further configured to reduce the occurrence of plugging, eddies, and/or non-uniform regions of reactants and associated hot spots within the reactor body by providing improved distribution of catalyst, reactor internals, and reactants during the reaction.

The reactor embodiments of the present disclosure further address shortcomings with existing reactor designs with respect to process control and temperature measurement. In some embodiments, the reactor is configured to provide one or more thermocouple wells configured to receive one or more respective thermocouples. Thermocouples may be configured to measure the temperature inside the reactor at multiple locations using a single thermocouple well disposed axially or longitudinally with respect to the reactor body, respectively.

An exemplary embodiment according to the present disclosure is directed to a reactor including a shell defining an interior space, at least one inlet nozzle, and a tube bundle including one or more tubes.

In one embodiment, the reactor further comprises a catalyst support plate.

In one embodiment, the reactor further comprises at least one tube support plate.

In one embodiment, the reactor further comprises a gas inlet plate.

In one embodiment, the reactor further comprises a top plate.

In one embodiment, the reactor further comprises a top plate and a tube support plate.

In one embodiment, the housing is configured to receive at least one catalyst.

In one embodiment, at least one catalyst is a solid catalyst. Such a catalyst may comprise spheres of a first diameter.

In one embodiment, the solid catalyst comprises spheres of a second diameter.

In one embodiment, the housing is configured to receive at least one solid catalyst. Such solid catalysts may comprise at least one of particulate, annular, plate-like or spherical shapes.

In one embodiment, the catalyst support plate is configured to support a height of solid catalyst.

In one embodiment, the catalyst support defines one or more openings.

In one embodiment, the one or more openings comprise a plurality of openings of a first size and a plurality of openings of a second size, the openings extending through at least a portion of the thickness of the catalyst support plate.

In one embodiment, the first dimension corresponds to a circumference of at least one tube in the tube bundle.

In one embodiment, the second dimension is smaller than the first dimension.

In one embodiment, the second dimension is a function of the thickness of the catalyst support plate.

In one embodiment, the openings of the first size are defined through the catalyst support plate in an arrangement of a plurality of tubes.

In one embodiment, the gas inlet plate includes a plurality of apertures defined through a thickness of the gas inlet plate.

In one embodiment, the plurality of apertures are circular apertures defined through the gas inlet plate according to an arrangement of the plurality of tubes.

In one embodiment, the gas inlet plate further comprises a second plurality of apertures defined through the thickness of the gas inlet plate, the second plurality of apertures comprising a different size and/or shape than the plurality of circular apertures.

In one embodiment, the housing defines an outlet nozzle.

In one embodiment, the outlet nozzle is located on a side of the housing.

In one embodiment, the inlet nozzle is located near the bottom of the housing.

In one embodiment, the inlet nozzle is arranged transverse to the flow direction through the housing.

In one embodiment, the inlet nozzle is substantially parallel to the flow direction through the housing.

In one embodiment, the gas inlet plate is arranged in the vicinity of the inlet nozzle.

In one embodiment, the at least one tube support plate comprises at least one circumferential band.

In one embodiment, the at least one circumferential band includes at least one bracket configured to extend around a portion of the tubes of the tube bundle.

In one embodiment, the at least one bracket extends around the entire tube.

In one embodiment, the housing defines an activation nozzle configured to provide a heating fluid.

In one embodiment, the reactor further comprises at least one catalyst unloading nozzle.

In one embodiment, the reactor further comprises a hand hole.

In one embodiment, at least one tube support plate defines a plurality of concentric circumferential bands.

In one embodiment, the tube bundle includes at least one first size tube and at least one second size tube.

In one embodiment, the inlet nozzle is disposed below the gas inlet plate.

In one embodiment, the housing defines an outlet nozzle, wherein the outlet nozzle is disposed below the catalyst support plate.

In one embodiment, a first size (e.g., diameter) of catalyst (e.g., spheres) and a second size (e.g., diameter) of catalyst (e.g., spheres) are disposed in discrete corresponding layers adjacent to the catalyst support plate.

In one embodiment, the housing is configured to receive at least one solid catalyst, wherein the catalyst has a first height within the housing in an unreduced state and a second height within the housing in a reduced state (e.g., due to settling that may occur during operation).

In one embodiment, the second height is lower than the first height.

In one embodiment, at least one tube support plate defines at least one radial strut connected to at least one of the plurality of circumferential bands.

In one embodiment, at least one radial strut is connected to at least one of the circumferential band and the outer support band.

In one embodiment, the innermost circumferential band of at least one tube support plate includes a number (e.g., 6) of brackets each configured to correspond to a ring of the same number of innermost tubes of the first size.

In one embodiment, the second circumferential band of at least one tube support plate includes the same or a greater number (e.g., 10) of brackets as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle that are located in the second concentric bands or rings of tubes. Such a tube may have a first size.

In one embodiment, the third circumferential band of at least one tube support plate includes the same or a greater number (e.g., 14) of brackets as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle that are located in the third concentric bands or rings of tubes. Such a tube may have a second size.

In one embodiment, the fourth circumferential band of at least one tube support plate includes the same or a greater number (e.g., 18) of brackets as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle in the fourth concentric band or ring of tubes. Such a tube may be of a first size.

In one embodiment, the fifth circumferential band of at least one tube support plate includes the same or a greater number (e.g., 22) of brackets as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle that are located in the fifth concentric band or ring of tubes. Such a tube may be of a first size.

In one embodiment, the sixth circumferential band of at least one tube support plate includes the same or a greater number (e.g., 26) of brackets as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle that are located in the sixth concentric band or ring of tubes. Such a tube may be of a first size.

In one embodiment, the seventh circumferential band of the at least one tube support plate includes the same or a greater number (e.g., 30) of brackets as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle that are located in the seventh concentric band or ring of tubes. Such a tube may be of a second size.

In one embodiment, the eighth circumferential band of the at least one tube support plate includes the same or a greater number (e.g., 34) of brackets as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle that are located in the eighth concentric band or ring of tubes. Such a tube may be of a first size.

In one embodiment, the ninth circumferential band of at least one tube support plate includes the same or a greater number (e.g., 36) of brackets as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle that are located in the ninth concentric band or ring of tubes. Such a tube may be of a first size.

In one embodiment, the tenth circumferential band of at least one tube support plate includes the same or a greater number (e.g., 42) of brackets as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle that are located in the tenth concentric band or ring of tubes. Such a tube may be of a first size.

In one embodiment, the tenth circumferential band of at least one tube support plate comprises the same or a greater number (e.g., 46) of brackets as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle in the eleventh concentric band or ring of tubes. Such a tube may be of a second size.

In one embodiment, the twelfth circumferential band of at least one tube support plate includes the same or a greater number (e.g., 50) of brackets as the previous circumferential band, which are respectively configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle that are located in the twelfth concentric band or ring of tubes. Such a tube may be of a first size.

In one embodiment, the thirteenth circumferential band of at least one tube support plate includes the same or a greater number (e.g., 54) of brackets as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle that are located in the thirteenth concentric band or ring of tubes. Such a tube may be of a first size.

In one embodiment, the tenth circumferential band of at least one tube support plate includes the same or a greater number (e.g., 10) of brackets as the previous circumferential band, each configured to correspond to the same number of concentric bands (e.g., rings) of the tube bundle in the fourteenth concentric band or ring of tubes. Such a tube may be of a second size.

Obviously, any number of circumferential bands may be provided.

In one embodiment, any one of the circumferential bands of the at least one tube support plate further comprises a cradle corresponding to the at least one thermocouple insertion tube configured to receive a temperature measurement device. Such thermocouple insertion tubes may have similar dimensions relative to the tubes of the tube bundle (e.g., the first or second sized tubes).

In one embodiment, at least four tube support plates are arranged longitudinally along the tube bundle.

In one embodiment, the at least one tube support plate is disposed longitudinally along the tube bundle, wherein the circumferential band of the at least one tube support plate further comprises a bracket corresponding to the at least one thermocouple insertion tube, wherein the at least one thermocouple insertion tube is configured to receive a temperature measurement device.

In one embodiment, the temperature measuring device is configured to obtain temperatures at a plurality of longitudinal locations within the reactor.

In one embodiment, the temperature measurement device is configured such that temperatures are available at a plurality of locations (e.g., at least eight different locations) along the longitudinal direction of the reactor, for example.

In one embodiment, the housing defines at least one flange to facilitate connection and disconnection of the upper portion of the housing from the body portion of the housing.

In one embodiment, the housing is configured to connect to a skirt at a bottom portion of the housing.

In one embodiment, the skirt defines an aperture configured to receive the inlet spool.

In one embodiment, the at least one tube support plate defines at least one radial strut connected to at least one of the plurality of circumferential bands of the tube support plate, wherein the at least one radial strut of the at least one tube support plate is axially aligned with the at least one radial strut of the other tube support plate.

In one embodiment, at least one radial strut of at least one tube support plate is axially offset relative to at least one radial strut of an adjacent tube support plate.

In one embodiment, at least one tube support plate defines a plurality of radial struts symmetrically arranged about the longitudinal axis of the reactor.

In one embodiment, the at least one tube support plate defines at least one radial strut connected to at least one of the plurality of circumferential bands of the tube support plate, wherein the at least one circumferential band of the at least one tube support plate is removably secured to the at least one radial strut.

In one embodiment, at least one tube of the tube bundle defines a longitudinal uniform thickness within the reactor.

In one embodiment, at least one tube of the tube bundle defines a longitudinal taper of thickness within the reactor.

In one embodiment, at least one tube of the tube bundle is configured to facilitate a greater degree of heat transfer near the bottom of the reactor relative to the top of the reactor.

In one embodiment, the reactor includes a housing defining an interior space configured to receive a catalyst, wherein a dome-shaped head including a motive nozzle includes a flange for removable connection to a reduced flange. The start-up nozzle comprises a manhole port through which maintenance personnel can access the reactor shell. The reactor also includes an inlet nozzle, and a tube bundle comprising a plurality of tubes arranged in concentric bands about a longitudinal axis of the reactor.

In one embodiment, the dome-shaped head is integral with the housing (e.g., formed entirely of one piece of material) without any connecting flange therebetween. Such a configuration reduces flange area, reduces any potential leakage points, provides a simplified design, and reduces cost. Such a reduction in flange diameter (which makes the diameter of the flange only the diameter required for the manhole port, e.g. about 40-80 cm) also ensures that the reactor head attached to the shell at such flange is lighter in weight and easier to operate, manufacture and maintain than a construction where the entire dome head is attached to the reactor shell by a separate flange (which may require a much larger diameter flange, e.g. about 2 meters).

In one embodiment, the domed head includes at least one thermocouple port, wherein the thermocouple port is inclined at an angle relative to the longitudinal axis of the reactor (e.g., inclined relative to vertical).

In one embodiment, the domed head includes two such thermocouple ports, each inclined relative to the longitudinal axis of the reactor.

In one embodiment, a reactor includes a housing defining an interior space configured to receive a catalyst, at least one inlet nozzle, and a tube bundle including a plurality of tubes arranged in concentric bands about a longitudinal axis of the reactor. The reactor also includes a catalyst support plate including a plurality of openings therethrough through which the plurality of tubes of the tube bundle pass. Each tube also passes through a plurality of tube support plates that are positioned above the catalyst support plates. A support ring is attached around each tube passing through the respective openings of the catalyst support plate and the tube support plate, wherein the tubes are not fixed (e.g., welded) relative to the catalyst support plate or the tube support plate to enable thermal expansion of the tubes passing through the catalyst support plate and the tube support plate.

In one embodiment, each tube includes an upper support ring and a lower support ring that are attached to and extend around each tube at a location where each tube passes through the catalyst support plate and at a location where each tube passes through the tube support plate. The upper support ring is located above the corresponding catalyst support plate or tube support plate and the lower support ring is located below the corresponding catalyst support plate or tube support plate, wherein the spacing between the upper support ring and the lower support ring connected to a particular tube is greater than the thickness of the corresponding catalyst support plate or tube support plate. This allows the tubes to slide within the openings of the plates to accommodate the different thermal expansions that may occur with respect to the plates for different tubes.

In one embodiment, a reactor includes a housing defining an interior space configured to receive a catalyst, at least one inlet nozzle, and a tube bundle including a plurality of tubes arranged in concentric bands about a longitudinal axis of the reactor. At least one tube support plate is also provided, each tube support plate including a plurality of apertures formed therethrough. Each of the plurality of tubes of the tube bundle passes through a corresponding opening in the tube support plate. The reactor further comprises at least one sliding bar at the outer periphery of the tube support plate, wherein the at least one tube support plate comprises a groove formed at the outer periphery of the tube support plate for receiving the corresponding sliding bar. In one embodiment, each tube support plate may include such a slot.

In one embodiment, each slide bar further comprises a slot or opening of its own for receiving the thickness of a respective tube support plate, wherein the height of the opening in the slide bar is greater than the thickness of the respective tube support plate. Such a configuration allows the slider bar to slide up or down relative to the tube support plate, which is captured within the opening of the slider bar. The distance associated with the height of the opening determines how far the slider bar can slide relative to the tube support plate. Such sliding bars also simplify the assembly of the reactor and the tube bundle.

In one embodiment, the at least one tube support plate comprises a top tube support plate and one or more intermediate tube support plates positioned below the top tube support plate. As described herein, a top plate may be provided in addition to the top tube support plate. The height of the opening of the slide bar corresponding to the top tube support plate is approximately equal to the thickness of the top tube support plate such that the top tube support plate is fixed relative to the slide bar. The size of the opening configured to receive the sliding bar of the other tube support plate (below the top tube support plate) is larger than the size of the opening associated with the top tube support plate so that the sliding bar can slide relative to the other tube support plate.

Any of the features mentioned above or other features described herein may be used in combination with each other, alone or in combination with other features.

Other methods, embodiments, and variations of the present system are described in more detail in the following discussion.

Drawings

These and other features, aspects, and advantages of the present utility model will become apparent and better understood with regard to the following description, appended claims, and accompanying drawings.

Fig. 1A is a perspective view of a reactor according to one embodiment of the present disclosure.

FIG. 1B is a perspective view of the reactor according to the embodiment shown in FIG. 1A after being rotated by one angle.

Fig. 2 is a plan view of a reactor according to the embodiment shown in fig. 1A.

FIG. 3 is a side cross-sectional view of the embodiment of FIG. 1A taken along line 1A-1A showing the reactor and reactor internals.

FIG. 4 is a side cross-sectional view of the embodiment of FIG. 1A taken along line 1A-1A showing the reactor, catalyst bed, and catalyst support layer.

Fig. 5A is an enlarged side cross-sectional view of a portion IV of the reactor of the embodiment shown in fig. 1A.

Fig. 5B is an enlarged side cross-sectional view of part III of the reactor of the embodiment shown in fig. 1A.

Fig. 6 is a perspective view of a tube bundle for a reactor according to the embodiment shown in fig. 1A.

Fig. 7 is a side view of the tube bundle of the embodiment of fig. 6.

Fig. 8 is a perspective view of a tube bundle and tube support plate according to the embodiment shown in fig. 6.

FIG. 9 is a plan view of a feed tube support plate at the top of the reactor according to the embodiment shown in FIG. 1A.

Fig. 10A is a plan view of a tube support plate according to the embodiment shown in fig. 6.

Fig. 10B is a plan view of a tube support plate according to another embodiment.

Fig. 11 is a plan view of a gas inlet plate of the reactor according to the embodiment shown in fig. 1A.

FIG. 12 is a plan view of a catalyst support plate of the reactor according to the embodiment shown in FIG. 1A.

Fig. 13 is an enlarged plan view of a portion XII of the catalyst support plate.

Fig. 14 is an exploded perspective view of a top plate and a reactor according to the embodiment shown in fig. 1A.

Fig. 15 is a plan view of the top plate of the embodiment shown in fig. 14.

Fig. 16 is an enlarged exploded perspective view of a partial XIV for the top plate of the reactor according to the embodiment shown in fig. 1A.

FIG. 17 is a side cross-sectional view of a restrictor plate for a nozzle of a reactor in accordance with the embodiment shown in FIG. 1A, taken along line 16A-16A.

Fig. 18 is a view of a restrictor plate and nozzle according to the embodiment shown in fig. 17.

Fig. 19 is a perspective view of a restrictor plate and nozzle according to the embodiment shown in fig. 17.

FIG. 20 is a side cross-sectional view of a reactor, catalyst bed, and thermocouple insertion tube according to another embodiment.

FIGS. 21A-21B are perspective views similar to FIGS. 1A-1B, but showing an alternative reactor configuration.

Fig. 22 is a side cross-sectional view similar to fig. 5A-5B, but showing an alternative reactor configuration to that shown in fig. 21A-21B.

Fig. 23 shows a cross-sectional view of an alternative reactor configuration.

Fig. 24 shows a view of a tube bundle similar to that shown in fig. 7, but including sliding bars disposed at the outer periphery of the tube bundle and tube support plates.

FIG. 25 shows a top plan view of an exemplary top feed tube support plate similar to that shown in FIG. 8, but including a slot for a slider bar.

FIG. 26 shows a top plan view of a feed tube support plate that can be used with other examples, also including slots for sliding bars.

Fig. 27 shows details of an exemplary slot, for example, included in the support plate shown in fig. 25 and 26.

Fig. 28 shows a detail of the support plate of fig. 26.

FIG. 29 is a partial detail view showing the support ring attached to the feed tube, the slot for the slide bar, and the slide bar itself.

Fig. 30 shows an exemplary configuration of the slider bar.

Fig. 31A shows the engagement between the slider bar and the top tube support plate.

FIG. 31B shows the engagement between the slider bar and the intermediate tube support plate, and also shows the position of the support ring attached to the feed tube relative to the slots in the slider bar 220.

Fig. 31C shows the engagement between the slider bar and the lowest tube support plate.

Detailed Description

Various embodiments of the present utility model will be better understood from the following description and drawings, in which like reference numerals refer to like numerals.

While the disclosure is susceptible to various modifications and alternative constructions, certain illustrated embodiments thereof are shown in the drawings and will be described below. It should be understood, however, that the disclosure is not limited to the disclosed embodiments, but, on the contrary, the disclosure is to cover all modifications, alternative constructions, compositions, and equivalents falling within the spirit and scope of the disclosure and defined by the appended claims.

It will be understood that, unless a term in this patent is defined to have the meaning described, it is not intended to limit the meaning of that term beyond its plain or ordinary meaning, whether explicit or indirect.

Turning to FIG. 1A, a reactor 100 according to an embodiment of the present disclosure is shown. The reactor 100 includes a housing 102 defining an interior space 103 (see fig. 4) and includes at least one inlet nozzle 120. The reactor 100 is configured to receive and mate with at least one reactor internal component, such as a tube bundle 130 (fig. 3) comprised of one or more tubes 131. The reactor 100 extends longitudinally about an axis 1A-1A from a top end 105 to a bottom end 107 and may define a generally cylindrical shape.

Inlet nozzle 120 is disposed generally proximate bottom end 107 such that one or more reactants may enter through inlet nozzle 120 and then move upwardly within one or more tubes 131 in direction F1 through interior space 103 (FIG. 4) of reactor 100 and then exit tube 131 near upper end 105 and turn downwardly in direction F2 to outlet nozzle 124, which defines a corresponding flange 125. As the reactants move upward through the one or more tubes 131, the reactants exchange heat with the catalyst and the reactants and products moving downward in direction F2 (fig. 4).

In exothermic reactions such as methanol synthesis, the reactants advantageously absorb heat generated by the reaction within the tubes 131 to preheat the reactants prior to delivery to the catalyst bed 140. This also advantageously mitigates the formation of catalyst hot spots, and associated catalyst sintering and product degradation. This also reduces the likelihood of a runaway reaction occurring because the reactants are the heat exchange medium for removing heat from the catalyst bed. Due to the distribution of the tubes 131, the heat exchange pattern formed by the reactants is much more efficient than, for example, a cooling water jacket surrounding the reactor 100.

In addition to the inlet nozzles 120 and the outlet nozzles 124, the reactor 100 also defines one or more catalyst unloading nozzles 116, and/or one or more hand holes 118 through which the interior space 103 may be accessed. The one or more catalyst unloading nozzles 116 may be downwardly sloped in order to facilitate gravity-based removal of catalyst from the catalyst bed 140, such as when spent catalyst is removed and refilled. The one or more hand holes 118 may facilitate servicing by allowing a technician to insert a hand, tool, or instrument into the interior space 103 proximate the catalyst support plate 154, the catalyst bed 140, or any other suitable location.

As shown in fig. 1A and 1B, the reactor 100 defines a start-up nozzle 110 configured to provide a heating fluid. During start-up operations, when the reaction has not reached steady state operation, the reactants may not be preheated as they move in the direction F1 in the tube bundle 130. The start-up nozzle 110 may receive a heating fluid, such as an inert gas, e.g., heated nitrogen, that may pass through the interior space 103 and provide sufficient enthalpy to achieve steady state operation without adversely affecting the yield of the reaction.

The housing 102 may also define at least one thermocouple port 106. Each thermocouple port 106 may facilitate insertion of a temperature measurement device into the reactor 100, and in some embodiments into the tube bundle 130 in an axial or longitudinal direction. By providing a thermocouple port 106 at the top 105 of the reactor 100, a single temperature measurement device (e.g., thermocouple) may be inserted through the port and be able to measure temperature at multiple locations. In some embodiments, the temperature measuring device may extend in an elongated manner and include a plurality of measuring means, such as thermocouples, thereon at predetermined distances, such that reactor conditions at each of said predetermined distances may be measured to improve control of the reaction.

Although two thermocouple ports 106 are shown in fig. 1A and 1B on opposite sides of the activation nozzle 110, it will be appreciated that more or fewer thermocouple ports 106 may be provided at any suitable location. By providing a temperature measurement device through thermocouple port 106, reactor 100 may advantageously allow for measuring reactor conditions at different height locations of the reactor while minimizing the number of thermocouple junctions, thereby facilitating improved process control and yield while minimizing the risk of leakage (whether into or out of housing 102). The location of thermocouple ports 106 also allows for sampling of reactor conditions at a desired radial location of reactor 100, regardless of the size of reactor 100, as opposed to existing reactor designs in which thermocouples are inserted radially, which allows for large reactors to be sampled too close to the housing.

Referring to fig. 4, the housing 102 may define an inlet nozzle 120 having a flange 121 disposed a distance below a gas inlet plate 156, both of which are disposed proximate the bottom end 107 of the reactor 100. The inlet nozzles 120 may be arranged transversely with respect to the longitudinal extension direction of the reactor 100 such that when reactants enter through the inlet nozzles 120 in the flow direction F4, the reactants change direction and enter the one or more tubes 131 of the tube bundle 130 through the gas inlet plates 156 in the direction F1.

The inlet nozzles 120 may be arranged as shown to optimize the distance between the inlet nozzles 120 and the bottom of the tube bundle 130 and to distribute the reactants evenly into the tubes 131 to avoid eddies that would cause plugging, hot spots and uneven flow. Flange 121 may be configured to facilitate connection of reactant feed lines to inlet nozzle 120. While the inlet nozzle 120 has been shown and described, it is understood that the distance between the inlet nozzle 120 and the bottom of the tube bundle 130 may be set to be greater or lesser as the case may be.

Additionally or alternatively, the housing 102 also defines a secondary inlet nozzle 132 having a corresponding flange 133, as shown in FIG. 5A. Flange 133 may be configured to facilitate connection of reactant feed lines to nozzle 132. The secondary inlet nozzle 132 is arranged to deliver reactants perpendicularly in a direction F3, which may correspond to or be parallel to the upward flow direction F1 through the tube 131. The reactor housing 102 may be secured by a skirt 108, which may define an aperture 122 through its thickness, configured to receive an inlet spool 135 connected to a secondary inlet nozzle 132.

The skirt 108 may be cylindrical and extend downwardly from the bottom end 107 generally coexisting with the reactor housing 102. The skirt 108 may define a ring 109 for securing the reactor 100 and skirt 108. The inlet spool 135 may be arcuate such that reactants are fed to the reactor 100 in a flow direction that is generally transverse to the flow direction F3, such as in a direction substantially parallel to the direction F4 of the inlet nozzle 120. The inlet nozzle 120 and the secondary inlet nozzle 132 may be configured to operate simultaneously or independently. Although a skirt has been shown and described, any suitable support may be utilized and the present disclosure is not limited to the use of a skirt.

In some embodiments, a flow divider 137 is removably disposed within the secondary inlet nozzle 132 or the housing 102 for directing the flow direction of the reactants when the secondary inlet nozzle 132 is in use. The flow divider 137 may define a shape that distributes a portion of the reactant flow radially outward from the secondary inlet nozzle 132 so that the flow is evenly distributed between the central tube (which is generally aligned with the secondary inlet nozzle 132) and the outer tube. Although the flow divider 137 has been shown and described, it is to be understood that any suitable structure, construction, or arrangement may be used. In some embodiments, the flow divider 137 defines a plurality of apertures and/or protrusions configured to distribute the reactant flow entering through the nozzles 132.

Referring to fig. 5B, the reactor 100 may also include a domed head 104 that is detachable from the housing 102 and releasably attachable thereto at flanges 112, 114, which may include any suitable structure for connecting the domed head 104 and the housing 102, such as holes and corresponding fasteners. The dome head 104 may define a space 113 above the top of the tube bundle 130. The space 113 provides a space for the preheated reactants to mix and flow back down through the catalyst bed 140. As previously described, the nozzle 110 may be defined by the thickness of the dome head 104 to allow for the addition of heating medium during the start-up operation.

While a dome-shaped head has been shown and described as releasably secured to the housing, it is to be understood that the disclosure is not so limited and that a secured head (e.g., including a flanged manhole) may alternatively be used for any size reactor.

The thermocouple ports 106 may be aligned with respective thermocouple insertion tubes 126, which may extend a distance above the top of the tube bundle 130. Thermocouple ports 106 may extend through some or all of the thickness of dome head 104 to allow access to reactor interior 103. Thermocouple port 106 may facilitate access to reactor interior 103 in any suitable manner, such as by defining an aperture sized to be flush with a surface of a temperature measurement device so that pressure may be maintained within reactor interior 103 by a sealing engagement with a gasket (or a combination thereof, or any other suitable manner). Any suitable means may be used. By extending a distance above the top of the tube bundle 130, the thermocouple insertion tube 126 is configured to be more easily identified when installing a thermocouple, particularly if the domed head 104 is installed resulting in limited access. Thermocouple insertion tube 126 may extend along the length of reactor 100 in substantial parallel or alignment with feed tube 131.

The reactor 100 may further include one or more of a catalyst support plate 154, at least one tube support plate 162, 163, 164, 165, a gas inlet plate 156, a top feed tube support plate 150 and/or a top plate 190, which are advantageously provided to facilitate securing the tube bundle 130 within the housing 102 while allowing access to the reactor interior 103 as necessary for maintenance or other purposes. The gas inlet plate 156 and the catalyst support plate 154 may advantageously be welded to the inner surface of the shell 102 to secure the tube bundle 130 therein.

The tubes 131 of the tube bundle 130 may be welded to the gas inlet plate 156, the top feed tube support plate 150, and/or at least one tube support plate 162, 163, 164, 165. In some embodiments, only the gas inlet plate 156 is welded or otherwise secured to the inner surface of the reactor housing 102, while the top feed tube support plate 150 and at least one tube support plate 162, 163, 164, 165 are not secured to accommodate thermal expansion of the tubes 131.

From fig. 4, the catalyst bed 140 may include one or more stages of catalyst, such as a solid catalyst. The catalyst bed 140 may additionally or alternatively include one or more inert sections 142, 144 that may include support ceramic spheres of a first diameter, such as 1-30 millimeters, more specifically 5-20 millimeters, or in some embodiments 9 millimeters. The catalyst bed 140 may also include support ceramic balls of a second diameter, such as 1-30 millimeters, more specifically 10-25 millimeters, or in some embodiments 19 millimeters. The catalyst bed 140 may define different sections 142, 144 that correspond to ceramic balls that comprise substantially only a single size.

For example, in the depicted embodiment, portion 142 includes substantially only spheres having a diameter of 9 millimeters, while portion 144 includes only spheres having a diameter of 19 millimeters. The sections 142, 144 may have any suitable height within the reactor 100, such as 5-500 millimeters, more specifically 100-300 millimeters, or in some embodiments the height of each section 142, 144 is 200 millimeters. The heights of the portions 142, 144 may be the same or different from one another. The catalyst bed 140 may additionally or alternatively comprise a solid catalyst having a shape comprising at least one of a particle, a ring, a sheet, or a sphere. The portions 142, 144 may be disposed adjacent (e.g., above or directly above) the catalyst support plate 154 and below the portion 141, with the portion 141 substantially comprising only solid catalyst having a shape and/or size different from the support ceramic balls of the portions 142, 144.

The portions 142, 144 of the support ceramic balls advantageously support the weight of catalyst in the catalyst bed while promoting efficient and uniform flow distribution. By providing different first and second portions 142, 144, the flow of reactants, products, and byproducts through the reactor interior 103 to the outlet nozzle 124 is improved because gas is allowed to flow between catalyst particles in the catalyst bed 140, between smaller first diameter support ceramic balls in the first portion 142, and finally between larger second diameter support ceramic balls in the second portion 144 before flowing through the catalyst support plates 154. Advantageously, the support ceramic balls are inert and are configured to resist thermal shock and corrosion of the various reactants, products, and/or byproducts. While supporting ceramic balls have been described, it is understood that the portions 142, 144 may have more or fewer portions and may include support structures of different shapes or sizes, such as rings, cylinders, polygons, or the like.

In some embodiments, the portion 141 of the catalyst bed 140 may have or define a first height 148 corresponding to the unreduced catalyst height and a second height 146 corresponding to the reduced catalyst height.

While the portion 141 of the catalyst bed 140 may comprise catalyst particles of a single size and/or shape, it is understood that different portions of catalyst particles of different sizes and/or shapes are contemplated as being disposed within the catalyst bed 140 within the scope of the present disclosure. The catalyst particles may have any suitable shape or configuration, such as spheres, particles, cylinders, clover, pyramids, cones, stars, and the like, and may have any suitable number and size of openings therethrough, and/or grooves or corrugations formed on a portion of the surface thereof. Different portions corresponding to a single, different type of catalyst size and/or shape may be provided in the catalyst bed 140, for example, as axial or radial layers or pockets. In some embodiments, catalyst particles of different sizes and shapes may be provided and mixed together in any suitable configuration within the catalyst body.

The catalyst particles in the catalyst bed 140 may function as and cooperate with the support ceramic balls in the sections 142, 144, or vice versa. In some embodiments, the catalyst particles are selected independently of the support ceramic spheres.

In fig. 6 and 7, a tube bundle 130 according to one embodiment is shown. The tube bundle 130 is configured to extend substantially longitudinally within the housing 102 about the axis 1A-1A and is held by the top and tube support plates 150, the plurality of tube support plates 162, 163, 164, 165, the catalyst support plate 154, and the gas inlet plate 156 in a top-to-bottom order. The distance 161 between the top plate and tube support plates 150 and the tube support plates 162, and the distance 161 between the tube support plates 162, 163, 164, and 165 may be uniform along the length of the tube bundle 130. In some embodiments, the distance 161 may vary. The distance 167 between the tube support plate 165 and the catalyst support plate 154 may be greater than the distance 161. The distance 169 between the catalyst support plate 154 and the gas inlet plate 156 may be less than the distance 167. It is to be understood that the described embodiments are merely exemplary and that any arrangement of tube bundles 130 may be used.

The tubes 131 may define a uniform thickness and diameter along the longitudinal length of the tube bundle 130. In some embodiments, the tubes 131 have a tapered thickness along the length of the tube bundle and an increased thickness and/or diameter near one or more of the plates 150, 162, 163, 164, 165, 154, 156 in order to support the plates. In some embodiments, one or more tubes 131 of the tube bundle 130 may have a greater thickness relative to other tubes 131 to enhance structural support. For example, the tubes 131 extending to near the center or outer edges of the tube bundle 130 may have a greater thickness relative to other tubes, such as 10%, 20%, 25%, 33%, 50% or any other suitable thickness, that is, the walls of these tubes 131 may have an increased thickness while maintaining the same inner diameter in some embodiments. This advantageously allows tubes 131 having an increased thickness to transport reactants while supporting tube bundle 130, thereby freeing up cross-sectional area relative to other structural arrangements to increase catalyst loading and more evenly distribute catalyst.

In some embodiments, the tubes 131 have a smaller thickness and/or increased diameter near the bottom of the reactor 100 as compared to the top of the reactor 100, for example, to facilitate more efficient heat transfer at the bottom of the reactor 100. Alternatively, one or more of the tubes 131 of the tube bundle 130 may include an inner tube rod configured to increase the velocity of the reactants preheated therein. The inner tube stick may extend a portion or all of the distance from the bottom of the tube 131 to the top of the tube 131.

The tube bundle 130 and the reactor 100 are advantageously constructed as modular in design and implementation. The existing shell-and-tube reactors are not easily scalable because significant reworking must be performed to achieve the proper balance between tube length and diameter, catalyst bed, shell and other components, while the design of the reactor 100 advantageously allows for scaling up or down depending on the placement of the concentric bands of tubes 131 on the tube bundle 130. The tube bundles 130 are arranged such that other geometric features of the reactor may remain unchanged, whether the circumferential band of tubes 131 is increased (to increase the capacity of the reactor design to increase production or during de-bottleneck modifications) or removed (to reduce the capacity of the reactor design). Thus, a large amount of redesign work can be avoided.

The tube bundle 130 may be configured to maintain one or more geometric constraints or ratios in any design, whether the reactor and tube bundle are configured in various designs for reduced or increased production. To ensure improved tube density, the average tube spacing (i.e., the center-to-center distance between the tubes) of the tube bundle may be substantially constant throughout the tube bundle, with the circumferential bands and the tubes forming such bands being spaced apart to maintain a constant tube spacing.

As another example, the tube bundle 130 advantageously achieves a desired ratio of the cumulative cross-sectional area of the catalyst bed when the reactor is viewed in plan view to the cumulative cross-sectional area of the tubes 131 (i.e., the total radial surface area of the tubes) viewed in the same plan view. In some embodiments, the ratio of the cumulative cross-sectional area of the catalyst to the cumulative cross-sectional area of the tube is between 2 and 20, more specifically between 5 and 12.

Whether circumferential bands of tubes 131 are added or removed in the design of the tube bundle 130, the cross-sectional area of the tubes 131 relative to the catalyst bed can be simply and easily adjusted to remain within a suitable range so that the performance of the reactor (and in particular its safety performance) is appropriate. In one embodiment, the addition or removal of the circumferential bands of one or more tubes may not substantially change the ratio of the cumulative cross-sectional area of the catalyst to the cumulative cross-sectional area of the tubes. In other embodiments, the tube bundle 130 may be designed to target any other geometry or process related parameters, whereby removing or adding circumferential bands of tubes does not require extensive redesign, but rather allows an engineer to simply and easily adjust the reactor to achieve new, desired capacities or other requirements. By providing the tube bundles 130 to provide a specific relationship between the cross-sectional areas of the tubes and the catalyst bed, the heat distribution can be improved, which reduces the likelihood of runaway reactions by reducing hot spots and increasing the overall yield of the reactor 100.

The reactor 100 may be controlled and maintained during operation to control one or more characteristics of the catalyst bed 140 and/or the tube bundle 130. In some embodiments, the reactor 100 is configured to utilize a temperature measurement device to evaluate the heat distribution across the cross-sectional area of the catalyst bed. In particular, the reactor 100 may be controlled by assessing the radial temperature gradient within the reactor as a function of depth and/or assessing the increase in gradient as a function of depth within the reactor 100 (from the upper end 105 to the lower end 107).

Referring to fig. 12 and 13, the catalyst support plate 154 is configured to support the overall height of the solid catalyst, e.g., the height of the sections 142, 144 in combination with the height of the section 141. The catalyst support plates 154 also advantageously support forces due to pressure differentials across the catalyst bed 140. The catalyst support plate 154 may be disposed within the housing 102 proximate to the catalyst discharge nozzle 116 and/or the hand hole 118. The catalyst support plate 154 may define one or more apertures 180, 181. The apertures 180, 181 may include or define apertures including a plurality of apertures corresponding to a first size of the apertures 180 and a plurality of apertures corresponding to a second size of the apertures 181 that extend through at least a portion of the thickness of the catalyst support plate 154.

The first dimension of the aperture 180 may correspond to the circumference of the at least one tube 131 of the tube bundle 130. In some embodiments, the first dimension of the aperture 180 is greater than the circumference of the tube 131 to allow some degree of movement and/or thermal expansion of the tube within the aperture 180. The apertures 180 may be defined through the catalyst support plate 154 according to the arrangement of the plurality of tubes 131 in the tube bundle 130. The second size of the openings 181 may be smaller than the first size of the openings 180, the second size of the openings 181 being configured to allow reactants, reaction products, and reaction byproducts to flow through in the process of flowing to the outlet nozzle 124.

In some embodiments, one or more apertures 180 may define a terminal for a temperature measurement device. The aperture 182 is sized and configured to receive the thermocouple insertion tube 126 and terminate extension of the thermocouple insertion tube 126 (fig. 7). In some embodiments, the apertures 182 may extend only partially into the thickness of the catalyst support plate 154. In some embodiments, the thermocouple insertion tube 126 may be welded to the catalyst support plate 154 and plugged there. The tubes 131 may not be welded to the catalyst support plate 154 to accommodate the effects of thermal expansion.

The size of the openings 181 and/or the average distance between the openings 181 may be a function of the thickness of the catalyst support plate 154, whereby the size of the openings 181 is proportional to the thickness of the catalyst support plate 154 and/or the distance between the openings 181 is inversely proportional to the thickness of the catalyst support plate 154. That is, the greater the thickness of the catalyst support plate 154, the greater the diameter of the openings 181 and/or the smaller the distance between the openings 181. In some embodiments, the catalyst support plate 154 may have a thickness of between 20 and 500 millimeters, more specifically between 50 and 300 millimeters, in some embodiments 110 millimeters, and the apertures 181 may have a diameter of 1-50 millimeters, more specifically 5-25 millimeters, in some embodiments 10 millimeters.

As shown in the enlarged partial view of fig. 13, the openings 180 may extend in a pattern or arrangement corresponding to the arrangement of the tubes 131 in the tube bundle 130, as will be discussed in greater detail below. An aperture 181 may extend between each aperture 180. The apertures 181 may define any suitable pattern or arrangement, such as an extension direction 183A and/or a lateral extension direction 183B, wherein the extension directions 183A, 183B define a straight line. Other patterns or arrangements of apertures 181 are also contemplated within the scope of the present disclosure. The apertures 181 may be spaced apart from one another by any suitable distance, in some embodiments, a center-to-center distance of 1-30 millimeters, more specifically, a center-to-center distance of 5-20 millimeters, and in some embodiments, a center-to-center distance of 15 millimeters for adjacent apertures 181 in one or both directions 183A, 183B. The center-to-center distance of adjacent openings 181 need not be uniform across the surface of the catalyst support plate 154, but may be varied as appropriate.

The catalyst support plate 154 may define a strip of material 184 at the periphery that forms a region of the catalyst support plate 154 that does not define any apertures 180, 181. The straps 184 may extend partially or entirely around the outer periphery of the catalyst support plate 154 and advantageously facilitate welding or other suitable connection of the catalyst support plate 154 to the inner surface of the housing 102. In some embodiments, the band 184 may extend into a recess defined by the inner surface of the housing 102 and then be welded thereto. The band 184 may extend any suitable distance, such as 5 millimeters in a radial direction.

Referring to fig. 11, a gas inlet plate 156 may be disposed below the catalyst support plate 154 and may include a plurality of apertures 155 defined through at least a portion of the thickness of the gas inlet plate 156. The plurality of apertures 155 may be circular apertures defined through the gas inlet plate 156 according to the arrangement of the plurality of tubes 131 of the tube bundle 130 and correspond to the arrangement of the apertures 180 in the catalyst support plate 154. In one embodiment, gas inlet plate 156 is substantially solid, without openings, outside of the plurality of openings 155 to force the entering reactants into tubes 131. The plurality of tubes 131 may be seal welded and/or strength welded to the gas inlet plate 156. It will be appreciated that seal welding, strength welding or a combination, or any other type of connection, is contemplated when welding one component to another component is discussed herein.

Referring to fig. 8 and 9, the reactor 100 may further include at least one tube support plate 150, 162, 163, 164, 165, which may be disposed longitudinally spaced apart along the axial or longitudinal length of the tube bundle 130. Although tube support plates 150, 162, 163, 164, 165 are shown and described, it is understood that more or fewer support plates may be provided. The top feed tube support plate 150 may be substantially identical to the tube support plates 162, 163, 164, 165 and may include or omit one or more features. For example, the top feed tube support plate 150 can have the same features as the tube support plates 162, 163, 164, 165, and can further include one or more spacers configured to operate in conjunction with the top plate, as will be described in more detail below.

The tube support plates 150, 162, 163, 164, 165 may include at least one circumferential band 168 configured to maintain the position of the at least one tube 131. The at least one circumferential band 168 includes at least one bracket 172 configured to extend around a portion of the tubes 131 of the tube bundle 130. In some embodiments, the at least one bracket 172 extends around the entire portion of the tube 131. The bracket 172 may be configured to be releasably connected to the tube 131.

In some embodiments, the bracket 172 may extend around only a portion of the tube, but not all. The brackets 172 may advantageously cooperate with beams 173 extending between the brackets 172 and adjacent brackets 172 connected to adjacent tubes 131. The brackets 172 may be releasably or non-releasably connected with the cross beam 173 and may define, for example, a rounded connection. The circumferential band 168 may be defined by a series of connected brackets 172 and beams 173 that define a substantially circumferential array with the respective tubes 131.

The circumferential bands 168 may be arranged concentric with adjacent circumferential bands 168 of the tube support plates 150, 162, 163, 164, 165, the circumferential bands 168 optionally being centered about the longitudinal axis 1A-1A of the reactor. The cooperation of the brackets 172, beams 173, radial struts 166, and circumferential bands 168 collectively define a tube support plate. While circumferential bands 168 have been shown and described, it is understood that any suitable configuration may be used, including asymmetric, staggered, or non-circumferential arrangements. While the cooperation of the various components is described as defining a tube support plate, it is to be understood that the tube support plate may take any suitable configuration and is not so limited.

The at least one tube support plate 150, 162, 163, 164, 165 defines at least one radial strut 166 connected to at least one circumferential band 168 at a connection point 169 and/or to an outer strut band 170 at a connection point 171. The tube support plate may define a plurality of radial struts 166 arranged radially symmetrically, such as in 22.5 ° increments, 30 ° increments, 45 ° increments, 90 ° increments, 120 ° increments, 180 ° increments, another increment of uniform bisection of 360 °, or others. In other embodiments, the radial struts 166 are asymmetrically arranged in any suitable manner.

The outer support band 170 may define a substantially continuous band of support material (e.g., stainless steel) that provides sufficient rigidity, strength, and/or support to the tube support plate and/or facilitates attachment of the outer support band 170 to the inner surface of the reactor housing 102. While eight radial struts 166 are shown and described in the embodiment shown in fig. 9 and 10, it is understood that more or fewer radial struts 166 may be provided and that all of the tube support plates 150, 162, 163, 164, 165 need not have the same number or arrangement of radial struts or other components.

The radial struts 166 may extend straight out from the center of the tube support plate to the outer support band 170 or may be defined as a curved, bent, circuitous, or other configuration. The radial struts 166 may be formed of any suitable material, such as stainless steel, and may provide heat resistance to maintain the desired hardness and strength under reactor conditions. The radial struts 166 advantageously define a connection point 169 between the circumferential band 168 and the radial struts 166. The connection points 169 may be releasable or non-releasable and may define any suitable connection, such as being welded together or being connected by suitable fasteners. The tube support plate may be configured to move with the tube 131 by thermal expansion and contraction, and may be formed of a high temperature resistant material, such as steel (e.g., stainless steel), ceramic, polymeric material, composite material, or others.

In some embodiments, the tube support plates 150, 162, 163, 164, 165 may be manufactured using any suitable method. In some embodiments, the tube support plates 150, 162, 163, 164, 165 are formed from a single solid plate, with material therein removed, such as by water jet cutting. In other embodiments, the radial struts and circumferential bands are manufactured and assembled separately to form the tube support plate.

The top feed tube support plate 150 can additionally define one or more spacers 174 on its top surface. The spacer 174 may be attached to one or more structures of the top feed tube support plate 150 in any suitable manner, including by welding. The spacer 174 may extend a predetermined height and may define an aperture in a central portion thereof. The aperture may include one or more threads configured to matingly engage with one or more threads of a fastener, as will be discussed in greater detail below with respect to the top plate 190. The spacer 174 may extend around the top feed tube support plate 150 in any suitable arrangement and in any suitable number.

For example, when the spacer 174 is connected to the radial strut 166, the spacer 174 may define three concentric annular patterns 175 (fig. 9) around the top feed tube support plate 150. In one embodiment, the spacer 174 extends along four radial struts 166 between the first and second circumferential bands, between the seventh and eighth circumferential bands, and between the thirteenth and fourteenth circumferential bands. A total of four spacers 174 may be provided on each concentric annular pattern 175 such that the corners of each segment of the top plate 190 may be secured thereto, as described below.

The arrangement of radial struts 166 advantageously provides for reliable connection of the tubes 131 of the tube bundle 130 while minimizing disruption to the catalyst distribution when loading catalyst from the top 105 of the reactor 100. For example, the radial struts 166 are configured to minimize uneven distribution of catalyst when catalyst particles are poured into the housing 102. In some embodiments, the radial struts 166 of adjacent tube support plates 162, 163, 164, 165 may be axially aligned along the longitudinally extending length of the reactor 100.

In other embodiments, as shown in fig. 10B, the radial struts 167 of adjacent tube support plates may be offset from the radial struts 166 to promote even distribution of catalyst during loading. The degree of staggering may be of any suitable degree. In some embodiments, the radial struts 167 are offset a distance corresponding to half the angular distance between the radial struts 166. In the embodiment shown in fig. 10B, radial struts 166 are offset 45 ° from each other and radial struts 167 are offset 22.5 °. The subsequent tube support plates may be alternately arranged. The radial struts 166 of adjacent tube support plates may be staggered along the longitudinal length of the reactor to define a helical or coiled pattern. The described embodiments are exemplary and any other arrangement may be suitably used.

The tube bundle 130 may be arranged such that the innermost circumferential band 168A of at least one tube support plate includes six brackets configured as rings of six innermost tubes, respectively, corresponding to the first size. The first dimension may be, for example, 0.5-3 millimeters in diameter, more specifically 1-2 millimeters in diameter, and in some embodiments 1.5 millimeters. The second circumferential band 168B of at least one tube support plate includes 10 brackets configured to correspond to loops of 10 tubes of the tube bundle of the first size, respectively. The third circumferential band 168C of the at least one tube support plate includes 14 brackets configured to correspond to loops of 14 tubes of the second size tube bundle, respectively. The second dimension may be, for example, 0.5-5 millimeters in diameter, more specifically 1-4 millimeters, and in some embodiments 2.5 millimeters.

The fourth circumferential band 168D of at least one tube support plate includes 18 brackets configured as rings of 18 tubes corresponding to the first size tube bundle, respectively. The fifth circumferential band 168E of the at least one tube support plate includes 22 brackets configured to correspond to loops of 22 tubes of the first size tube bundle, respectively. The sixth circumferential band 168F of the at least one tube support plate includes 26 brackets configured to correspond to loops of 26 tubes of the tube bundle of the first size, respectively.

The seventh circumferential band 168G of the at least one tube support plate includes 30 brackets configured to correspond to loops of 30 tubes of the second size tube bundle, respectively. The eighth circumferential band 168H of the at least one tube support plate includes 34 brackets configured to correspond to the rings of 34 tubes of the tube bundle of the first size, respectively. The ninth circumferential band 168I of the at least one tube support plate includes 36 brackets configured to correspond to loops of 36 tubes of the tube bundle of the first size, respectively. The tenth circumferential band 168J of the at least one tube support plate includes 42 brackets configured to correspond to loops of 42 tubes of the first size tube bundle, respectively.

The tenth circumferential band 168K of the at least one tube support plate includes 46 brackets configured to correspond to loops of 46 tubes of the second size tube bundle, respectively. The twelfth circumferential band 168L of the at least one tube support plate includes 50 brackets configured to correspond to loops of 50 tubes of the tube bundle of the first size, respectively. The thirteenth circumferential band 168M of the at least one tube support plate includes 54 brackets configured to correspond to loops of 54 tubes of the tube bundle, respectively, of the first size. The tenth circumferential band 168N of the at least one tube support plate includes 58 brackets configured to correspond to loops of 58 tubes of the second size tube bundle, respectively.

While first through fourteenth circumferential bands have been shown and described, it is to be appreciated that the reactor embodiments of the present disclosure advantageously facilitate modular reactor configurations that can better accommodate different production requirements for different facilities than existing reactor designs. For example, the engineers may modify the described tube bundle 130 to have more, fewer, and/or different circumferential bands, as desired. To scale up the tube bundle 130 and the overall reactor 100 to accommodate higher annual plant throughput (e.g., during de-bottleneck operations), additional circumferential bands may be added to increase the number of tubes and to expand the tube bundle outwardly with simple modifications. For example, the connection 171 between the radial strut 166 and the outer band 170 may be released, such that an additional circumferential band may be added to the tube support plate, i.e., the outer band 170 may be replaced with a new circumferential band. To this end, the outer band 170 may be configured to have an expandable circumference.

Conversely, to reduce the size of the reactor 100, circumferential bands, such as the outermost circumferential bands, may be removed to reduce the size of the tube bundle to fit smaller reactor shells and/or to produce correspondingly lower annual plant production. This can be achieved, for example, by removing the connection 169 between the circumferential band and the radial struts.

Furthermore, the arrangement of the circumferential bands as shown allows for the addition or removal of circumferential bands and associated brackets and tubes while accommodating the structure of the radial struts. As shown, the circumferential bands increase the number of brackets and tubes, provide a substantially uniform distribution of tube locations, and provide sufficient space between the tubes to allow catalyst and reactants to pass therebetween, and to allow the circumferential bands to be added or removed without substantially disrupting the design of the radial struts and tube support plates.

In one embodiment, the ninth circumferential band 168I (or any other) of the at least one tube support plate further includes a bracket 172 corresponding to the at least one thermocouple insertion tube 126, the at least one thermocouple insertion tube 126 being of a first tube size. Providing the thermocouple insertion tube 126 with the brackets 172 allows for insertion of a temperature measuring device into the tube bundle, preferably into the area of the tube bundle where the temperature measuring device will be surrounded by catalyst and tubes, in order to provide accurate temperature readings along the longitudinal length of the reactor.

Similar to the tube support plates 162, 163, 164, 165, the top feed tube support plate may include one or more radial struts 166, an outer band 170, and one or more brackets 172 configured to engage the tubes 131 of the tube bundle 130 and/or to surround the tubes 131. The radial struts 166 of the top feed tube support plate 150 may be arranged similarly or correspondingly to the struts 166 of the feed tube support plates 162, 163, 164, 165 and may be axially divided by a suitable angle 176 (fig. 9), for example 45 °. It is to be understood that other angles or arrangements are also contemplated by the present disclosure.

The legs 172 of the top feed tube support plate 150 may be configured or extend to near the terminal ends of the tubes 131 where the preheated reactant flows out of the tubes 131 and then downward in the second direction F2. Thermocouple insertion tube 126 may extend a distance above the uppermost distance or extent of tube 131, which facilitates insertion of a temperature measurement device from thermocouple port 106 into thermocouple insertion tube 126. As with the tube support plates 162, 163, 164, 165, the top feed tube support plate 150 may be configured to expand or contract in a manner that is appropriate to the size of the desired capacity of the reactor 100.

The arrangement of the tube bundles 130 and tube support plates 150, 162, 163, 164, 165 may advantageously take into account heat transfer and reactor dynamics of the reactor.

Turning to fig. 14-16, a top plate 190 is shown. The top plate 190 may be configured to be mounted on top of or above the top feed tube support plate 150. The top plate 190 may be modular in construction and defines four distinct portions 192 surrounded by flanges 191. The top plate 190 may define a plate edge 194, one or more tube apertures 202 defined through at least a portion of the thickness of the plate 190, and one or more gas apertures 204 defined through at least a portion of the thickness of the plate 190. The tube holes 202 may be configured to be generally aligned with the arrangement of the tubes 131 of the tube bundle 130 and facilitate the exit of the preheated reactants from the tubes 131 into the space 113 of the reactor 100 (fig. 5B).

The gas openings 204 facilitate the entry of the preheated reactants into the catalyst bed 140 and ensure proper flow distribution. The top plate 190 may be configured to create a small pressure drop to make the flow into the catalyst bed as uniform as possible. The top plate 190 is advantageously configured to achieve improved uniformity of flow distribution with the simplified design shown and described, as opposed to existing methods that utilize heavy and/or complex designs, which are difficult to manufacture or handle for maintenance purposes, and/or which are relatively costly.

Because the top plate 190 may extend outward to the flange 191, the gas apertures 204 may extend substantially to the edge 194, leaving no gap as the catalyst support plate 154. The thickness of the top plate 190 may be reduced as compared to the catalyst support plate 154. In some embodiments, the top plate 190 has a thickness of between 1 and 25 millimeters, more specifically between 5 and 15 millimeters, and in some embodiments 8 millimeters.

The top plate 190 is configured to be removably attachable to the housing 102 and/or the top feed tube support plate 150 by any suitable mechanism, such as by the use of fasteners 196 that mate with corresponding holes 193 (FIG. 15) at the edges of portions of the top plate 190. The fasteners 196 of the top plate 190 may mate with one or more spacers 174 extending between the top plate 190 and the top feed tube support plate 150 and may be welded (e.g., tack welded) to the top tube support plate 150.

In some embodiments, the spacer 174 can have a sufficient height and/or circumference to receive the mating ends of the fasteners 196 within a track or groove formed through a portion of the thickness of the spacer 174, which allows the top plate 190 to be securely attached to the top feed tube support plate 150. The height of the spacer 174 may be between 1 and 30 millimeters, more specifically between 5 and 20 millimeters, and in some embodiments 15 millimeters. The spacers 174 may be welded to the radial struts 166, the circumferential bands 168, the brackets 172, or elsewhere. As shown, the fasteners 196 and corresponding spacers 174 may be positioned such that the fasteners 196 and spacers 174 are provided at each corner of the top plate 190 and along the inner edges of the portion 194.

The top plate 190 may further include or operate in conjunction with one or more load rings 195. The load ring 195 may be any suitable component configured to facilitate positioning and/or removal of the portion 194 of the top plate 190. The load ring 195 may be connected by one or more gas apertures 204, or at any other suitable location, and defines a means for removably securing to the top plate 190 and manipulating the top plate 190. In some embodiments, the load ring 195 is configured to allow an operator to grasp the top plate 190 with a tool to lift the top plate 190 from the reactor housing 102.

By providing the top plate 190 in a modular manner, and having the top plate 190 with different portions 194, the top plate 190 is easier to disassemble and replace during maintenance operations without sacrificing the ability of the top plate 190 to distribute reactants and secure the catalyst bed 140. The modular construction of the top plate 190 further reduces the cost and complexity of the manufacturing process because the same portion 192 can be manufactured rather than a unitary construction of the plate 190. One benefit of providing the top plate 190 is that a factory worker can stand on one of the portions 194 of the top plate 190 while loading catalyst through the opening provided by the removed portion 194.

Turning to fig. 17-19, a restrictor plate 210 is shown and described that may be used with one or more nozzles of the reactor 100. The restrictor plate 210 may secure the catalyst discharge nozzle 116 and/or the hand hole 118. The restrictor plate 210 may include a handle 212 and be configured to mate with a lip 214 defined by the nozzle 116. In some embodiments, the nozzle 116 defines a plurality of lips 214 that are arranged circumferentially around the nozzle opening in any suitable manner, and the retainer plate 210 is configured to interface with an inner surface of the lips 214, as shown in fig. 17. In some embodiments, the lips 214 are spaced apart at an angle, such as 15 degrees, 20 degrees, 30 degrees, 45 degrees, 60 degrees, 90 degrees, or other angles. The arrangement of the lips 214 may be symmetrical or asymmetrical. Flange 117 of nozzle 116 may define one or more openings 211 through which suitable fasteners may be received to attach nozzle 116 to a suitable valve cartridge.

In some particular embodiments, the plurality of lips 214 do not extend around the bottommost portion B of the circumferential opening defined by the catalyst discharge nozzle 116 or the hand hole 118. In contrast, as shown in fig. 19, the bottommost portion B is unobstructed so that the catalyst particles can flow freely under the force of gravity during unloading of the catalyst. The provision of the limiting plate 210 advantageously prevents the catalyst from flowing too fast during the unloading of the catalyst.

Turning to FIG. 20, a reactor 300 according to one embodiment is shown and described. The series referenced 300 may include similar or identical features to the series referenced 100 already described. The reactor 300 includes a shell 302 in which a tube bundle having a ceiling 350 as described above may be received and secured and which defines an inlet nozzle 320 and an outlet nozzle 324. The housing 302 may further include or cooperate with a dome-shaped head 304 that defines and/or supports a thermocouple insertion nozzle 306. The dome head 304 may be secured to the housing 302 by a flange 312. Reactor 300 extends longitudinally about axis 20A-20A. The catalyst bed 340 may extend a suitable height within the interior space defined by the reactor housing 302.

The reactor 300 also defines a thermocouple insertion tube 326 that extends about, or is substantially parallel or aligned with, the longitudinal axis 20A-20A and passes through the catalyst bed 340. The thermocouple insertion tube 326 may be integrated with the tube bundle described above or separate from the tube bundle. Thermocouple insertion tube 326 is configured to receive temperature measurement device 310, which also extends about longitudinal axis 20A-20A. The temperature measuring device 310 may be a multi-point thermocouple. The multi-point thermocouple is configured to obtain temperature measurements at a plurality of locations along the reactor 300.

As shown in fig. 20, the temperature measurement device 310 may include eight measurement locations 382A, 382B, 382C, 382D, 382E, 382F, 382G, 382H along the length of the reactor 300 and extend to the terminus 327. The temperature measurement device 310 may have an overall length 330I. Locations 382A, 382B, 382C, 382D, 382E, 382F, 382G, 382H may be spaced apart by distances 330A, 330B, 330C, 330D, 330E, 330F, 330G, respectively. The distances 330A, 330B, 330C, 330D, 330E, 330F, 330G may be the same distance such that the measurement locations are evenly spaced along the reactor 300 or they may be different distances depending on the needs of a particular process.

Thermocouple insertion tube 326 may be suitably configured to allow temperature measurement device 310 to obtain readings at locations 382A, 382B, 382C, 382D, 382E, 382F, 382G, 382H, for example by defining an aperture in thermocouple insertion tube 326 at or near locations 382A, 382B, 382C, 382D, 382E, 382F, 382G, 382H to allow temperature measurement device 310 to be able to measure the temperature inside the reactor. Although a temperature measurement device has been described, it is to be understood that the present disclosure extends to other types of sensors and is not limited to multi-point thermocouples. In some embodiments, different sensors may be provided at different locations as desired.

The temperature measurement device 310, the reactor 300, and the thermocouple insertion tube 326 advantageously facilitate improved process control by providing: particulate reactor condition data is provided at a plurality of locations within the reactor while minimizing the risk of leakage, particularly for high pressure and/or high temperature environments and/or reactions involving hydrogen or oxygen sensitive catalysts, and reducing the number of thermocouple junctions. The configuration of the temperature measurement device 310, the reactor 300, and the thermocouple insertion tube 326 further improves the scalability of the reactor design because the placement of the thermocouple insertion tube 326 and the temperature measurement device 310 allows for accurate reading of the reactor internal conditions regardless of the size of the reactor, which alleviates the difficulty of monitoring the reactor where the thermocouple well is placed radially from the sidewall surface of the reactor, and for larger reactors, allows for disproportionate measurement of conditions that are close to the housing rather than close to the center of the reactor.

Furthermore, as shown at least in fig. 2 and 7, the reactor may comprise a plurality of temperature measuring devices. The temperature measuring means may be arranged in any suitable configuration relative to the reactor housing and relative to each other. For example, in the embodiment shown in fig. 2 and 7, the temperature measuring device may be offset the same distance from the central longitudinal axis of the reactor and disposed opposite. The distance between the temperature measuring devices may be configured to minimize interference or disturbance to the heat distribution within the reactor, particularly to the catalyst bed. The distance may be selected to be above a minimum threshold at which hot spots may occur between or near the temperature measurement devices due to interference with the reactant and product streams and corresponding heat distribution. Thus, setting the temperature measurement device above this minimum threshold avoids disruption of the reactor's performance and improves the accuracy of the measurement.

The temperature measuring devices may be used for different purposes and/or may complement each other. In the embodiment shown in fig. 2 and 7, the temperature measuring device is a multi-point thermocouple, as described with respect to fig. 20. One of the multi-point thermocouples may be connected to the process control system and a second multi-point thermocouple may be connected to the safety instrumented system.

Providing a plurality of multi-point thermocouples advantageously confirms temperature measurements for specific locations (i.e., heights) within the reactor. Any difference between the signals obtained from the multipoint thermocouples may be used, for example, to determine the development of hot spots at a particular elevation, allowing the operator to make adjustments as necessary. It will be appreciated that any suitable number of thermocouples may be used in any suitable configuration.

One embodiment of the reactor includes a plurality of feed tubes extending longitudinally through the reactor and the catalyst bed. The tube bundle may define a thermocouple insertion tube extending parallel to the feed tube and configured to receive a temperature measurement device, such as a multipoint thermocouple, therefrom. The thermocouple insertion tube may be configured to extend at different distances from the center of the reactor.

These distances may be configured to allow temperature profiles to be measured at different distances from the center. In particular, this may help to verify the design of the reactor at a particular scale, further enhancing the scalability of the reactor of embodiments of the present disclosure. This also enhances process control of the reactor, improves the granularity of temperature measurements, and enables tailoring of the associated response using the process control system. In some embodiments, the radial configuration of the thermocouple insertion tube may be determined so as to coincide with the predicted hot spot.

This allows the operator to quickly and accurately determine when a hot spot is forming and respond accordingly, thereby preventing a runaway reaction from occurring. The configuration of the thermocouple insertion tube may be further determined relative to the tube bundle to accommodate the size of the reactor shell. For example, in smaller reactors, fewer thermocouple insertion tubes may be used, while in larger reactors, the number of thermocouple insertion tubes and the complexity of their construction may increase.

FIGS. 21A-21B and 22 illustrate another reactor configuration, but have many similarities to the reactors described herein. The top of the reactor is modified compared to the reactor shown in fig. 3-4 to reduce the area where leaks may occur (e.g., between flanges 112 and 114), thereby providing a simplified reactor design and reducing costs. For example, in the embodiment shown in FIGS. 21A-21B and 22, the large mounting flanges 112, 114 are eliminated. Such a separate dome head 104 and associated flange is very expensive, heavy, and includes a large surface area that may form a potential leak point.

Instead of such a separate domed head, the reactor 100 'includes a domed head 104' that includes an activation nozzle 110 'having a flange 114', the flange 114 'being adapted to be removably connected to a reduced flange 112'. The start-up nozzle 110' includes a manhole access opening through which maintenance personnel can access the reactor housing 102. In fig. 21A-21B and 22, the domed head 104' is formed integrally with the housing 102 without any connecting flange therebetween. This difference relative to the reactor 100 provides the following benefits: reduced cost, simplified design, a detachable head with lighter weight, reduced likelihood of leakage, etc.

The manhole passage opening through the activation nozzle 110' may have a diameter of, for example, 40-80 cm. Such manhole ports can be used to facilitate inspection and catalyst loading of the reactor.

21A-21B and 22, the thermocouple ports 106 'on the domed head 104' may be inclined relative to the vertical longitudinal axis 1A due to the size of the flanges 112', 114'. Such a configuration still allows for measuring the temperature near the center of the reactor 100'. As shown, the reduced flange 112' is used to connect the service inlet pipe to the manhole port, making such port available for process connection, as well as for manhole access for inspection.

Because of the challenges in identifying and installing thermocouples, the thermocouple insertion tube 126 may be configured to extend to a greater height than the other tubes 131. With such manhole access, the process is simplified because a worker can enter the reactor to load catalyst and guide the flexible thermocouple into the appropriate tube. The flexibility of the thermocouple is beneficial, and can be guided through the angled thermocouple port 106' and then into the thermocouple insertion tube 126. The thermocouple is much easier to insert than other methods because the worker can access the top of the reactor through the manhole port.

As an example, the inclination of the thermocouple port 106' may be 5 to 30 degrees, or 10 to 20 degrees (e.g., about 15 degrees) with respect to the vertical. Of course, other angles may be selected, and those noted above are exemplary only.

Fig. 23 shows a bottom view of a reactor 100', which is similar to the configuration shown in fig. 4 and 5A.

Fig. 24-31C illustrate other aspects and features that may be included in any of the presently described reactors. For example, sliding bars 220 are provided at the outer periphery of the tube bundle 130 and tube support plates 162-165. Such sliding bars facilitate the assembly of the tube bundle and the reactor. Such a bar 220 also allows for thermal expansion, allowing the bar to slide up and down relative to a support plate to which it is slidably coupled. For example, as shown in FIGS. 25 and 26, the top feed tube support plate 150 and each additional or intermediate tube support plate 162-165 (shown in FIG. 26 as plates 162, as examples of all intermediate plates 162-165) may include one or more peripheral slots 222a-222d for receiving the slide bar 220. The illustrated construction includes 4 such slots 222a-222d for receiving 4 slide bars, two of which 222a and 222b are 30 degrees apart from each other and two other slots 222c and 222d are also 30 degrees apart from each other, on opposite sides of the tube bundle and reactor. As shown, slot 222a is 180 degrees apart from slot 222c, while slot 222b is 180 degrees apart from slot 222 d. Of course, other configurations may be used, including a different number of slots, slide bars, and positioning of such slots and slide bars.

FIG. 27 shows a partial enlarged view of a portion of the feed tube support plate 162 shown in FIG. 26, showing an exemplary slot 222c. FIG. 28 shows an enlarged view of a portion of the feed tube support plate 162 showing another configuration similar to that shown in FIG. 8.

Fig. 29 is an enlarged view of a portion showing the slide bar 220 within the slot 222a, and also showing how each feed tube 131 can include upper and lower support rings 224 welded or otherwise fixedly attached to the feed tube 131, both above and below a given feed tube support plate (e.g., plate 162 in the figures). The feed tube 131 itself may be slidably disposed relative to the plate 162, but the associated support ring 224 acts as a stop to limit movement of the feed tube relative to the support plate 162, for example to accommodate uneven thermal expansion. Each slide bar 220 is shown to include an opening 226 for receiving the thickness of the feed tube support plate 162, and the height of the opening 226 is greater than the thickness of the plate 162, so as to allow the slide bar 220 to slide up and down relative to the plate 162 depending on the size of such opening 226, for example, due to uneven thermal expansion. Thus, the slider 220 is not fixedly attached to the plate 162 (nor is the tube 131 fixedly attached to the plate 162), but both the slider and the tube are free to slide somewhat relative to the plate 162 within the limits set by the stops provided by the support ring 224 associated with the tube 131 and the stops provided at the ends of the opening 226 of the slider 220.

FIG. 30 shows the slide bar 220 and its associated opening 226 for engagement with each of the respective feed tube support plates 162-165. As shown, the top of the slider 220 also includes an opening 228 that, although not as large as the other openings 226, is approximately equal in height to the thickness of the top feed support plate 150 so that the top feed support plate 150 can be received within the slot 228 and secured relative to the slider, while the opening 226 is sized to be greater than the thickness of the respective received intermediate tube support plates 162, 163, 164 and 165, as shown, to allow some clearance and sliding movement between the slider 220 and such intermediate tube support plates 162-165. Each of the individual slider bars (e.g., 4) may be similarly configured. It can be seen from the figure that the sliding strips may not extend the full length of the tubes of the tube bundle 130, but may extend from the top plate 150 to the lower tube feed support plate 165, but that the sliding strips do not extend significantly below the plate 165 toward the catalyst support plate 154. For example, as shown in FIG. 24, neither the distance 167 between the feed tube support plate 165 and the catalyst support plate 154 nor the distance 169 between the catalyst support plate 154 and the gas inlet plate 156 may include a sliding bar.

Fig. 31A-31C show side cross-sectional views associated with the top of slider 220 (fig. 31A), the middle of slider 220 (fig. 31B), and the bottom of slider 220 (fig. 31C). The configuration shown in fig. 31B may be applicable to any number of intermediate tube support plates below the top tube support plate, as well as the lowest tube support plate (e.g., in the illustrated configuration, this may be applicable to plates 162, 163, and 164). By way of example, fig. 31A shows how the top feed support plate 150 is fixed relative to the slide bar 220, with the peripheral edge of such plate 150 fitting within the slot 228. Fig. 31B shows how intermediate plates 162, 163 and 164 cooperate with slide bar 220, wherein the peripheral edge of plate 162 is positioned within opening 226, but plate 162 and slide bar 220 are not relatively fixed, but slide bar 220 is free to slide up and down relative to the plate due to the height of opening 226 relative to the thickness of the plate. Fig. 31C shows the bottom of the slider 220, with the openings 226 of the plate 165 being similar in size, showing how the slider 220 does not extend significantly downward beyond the plate 165, but rather terminates at the plate 165.

By providing a reactor according to the disclosed embodiments, the problems of the existing reactor being difficult to access when maintenance is required and the reactor being difficult to expand according to the production needs of the facility are solved. The reactor embodiments of the present disclosure advantageously provide a reactor that includes robust and flexible reactor internals configured for modular arrangement according to the throughput requirements of a facility design, easy access for maintenance and catalyst loading, improved uniform distribution of catalyst, reactants and heat, and/or robust structural support during construction, transportation, installation and operation.

While the reactor has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes, equivalents, and modifications that come within the spirit of the embodiments defined by the following claims are desired to be protected.

Thus, features of the disclosed embodiments may be combined or arranged to achieve particular advantages as would be apparent to one of ordinary skill in the art from this disclosure. Likewise, features of the disclosed embodiments may provide independent advantages applicable to other embodiments not detailed herein. In particular, any feature from one disclosed embodiment may be used in other disclosed embodiments.

It should be understood that not necessarily all objects or advantages may be achieved in any embodiment of the disclosure. Those skilled in the art will recognize that the system and method may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught without achieving other objects or advantages as may be taught or suggested.

Those skilled in the art will recognize the interchangeability of various features disclosed. Other known equivalents of each feature, in addition to variations described, may be mixed and matched by one of ordinary skill in this art. Those skilled in the art will appreciate that the features described are applicable to other types of reactors, reaction fittings, chemical products and processes. Thus, the present disclosure and its embodiments and variations are not limited to methanol synthesis processes or shell-and-tube reactors, but may be applied to any chemical process.

While the present disclosure describes certain exemplary embodiments and examples of reactors, it will be understood by those skilled in the art that the present disclosure extends beyond the specifically disclosed embodiments to other alternative embodiments of the present disclosure and/or uses of the present disclosure and obvious modifications and equivalents thereof. The present disclosure should not be limited by the specific disclosed embodiments described above.

Furthermore, unless otherwise indicated, the terms used in the specification and claims should be understood to alternatively be modified by the term "about" or its synonyms. When the terms "about," "approximately," "substantially," or the like are used with a stated amount, value, or condition, it is understood that the amount, value, or condition deviates from the stated amount by less than 20%, less than 10%, less than 5%, less than 1%, less than 0.1%, or less than 0.01%. The term "between" as used herein includes any of the recited endpoints. For example, "between 2 and 10" includes both 2 and 10.

Claims

1. A reactor, comprising:

a housing defining an interior space configured to receive a catalyst;

at least one inlet nozzle; and

a tube bundle comprising a plurality of tubes arranged in concentric bands around the longitudinal axis of the reactor,

Wherein the reactor further comprises a catalyst support plate comprising a plurality of openings formed therethrough, a plurality of tubes of the tube bundle extending therethrough, a support ring being connected around each tube extending through a respective opening of the catalyst support plate, the tubes being unfixed relative to the catalyst support plate to permit thermal expansion of the tubes extending through the catalyst support plate.

2. The reactor of claim 1, wherein each tube comprises an upper support ring and a lower support ring connected to and extending around the tube, the upper support ring being located above the catalyst support plate and the lower support ring being located below the catalyst support plate, wherein the spacing between the upper and lower support rings for a given tube is greater than the thickness of the catalyst support plate.

3. A reactor, comprising:

a housing defining an interior space configured to receive a catalyst;

at least one inlet nozzle; and

wherein the reactor further comprises at least one tube support plate, each tube support plate comprising a plurality of apertures formed therethrough, each tube of the plurality of tubes extending through a respective aperture of the tube support plate, wherein the reactor further comprises at least one sliding bar at an outer periphery of the at least one tube support plate, the at least one tube support plate comprising at least one slot formed at the outer periphery of the tube support plate for receiving a respective sliding bar.

4. A reactor according to claim 3, wherein each of the sliding strips comprises an opening for receiving the thickness of a respective one of the at least one tube support plates, wherein the height of the opening in the sliding strip is greater than the thickness of the respective tube support plate.

5. The reactor of claim 4, wherein the at least one tube support plate comprises a top tube support plate and one or more additional tube support plates, the height of the opening of the sliding bar corresponding to the top tube support plate being approximately equal to the thickness of the top tube support plate such that the top tube support plate is fixed relative to the sliding bar, the height of the opening of the sliding bar configured to receive the additional tube support plate being greater than the thickness of the corresponding tube support plate such that the sliding bar is slidable relative to the additional tube support plate.

6. A reactor according to claim 3, wherein the reactor shell further comprises a domed head comprising a start-up nozzle having a flange, the flange being detachably connected to the reduced flange, the start-up nozzle comprising a manhole port through which a maintenance person can access the reactor shell.