US4199545A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Fluid-wall reactor for high temperature chemical reaction processes
Assignee: JM Huber Corp
•
Filing: 1977-05-02
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Granted: 1980-04-22
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Expires: 1997-05-02
Abstract
Abstract A fluid-wall reactor for high temperature chemical reactions is described, the reactor comprising (A) a porous reactor tube, at least a portion of the interior of which defines a reaction zone, the tube being made of a fabric of a fibrous refractory material; (B) a pressure vessel enclosing the reactor tube to define an inert fluid plenum, the pressure vessel having at least one inlet for admitting the inert fluid which is directed under pressure through the porous tube wall to provide a protective blanket for the inside surface of the reactor tube; (C) means for introducing at least one reactant into the reaction zone, the reactants being directed in a predetermined path axially of the reactor tube and being confined by the protective blanket substantially centrally within the reaction zone; (D) means disposed within the plenum for heating the reactor tube to the temperature level at which it emits sufficient radiant energy to initiate and sustain the desired chemical reaction, the radiant energy being directed into the reaction zone to coincide with at least a portion of the path of the reactants; and (E) a heat shield disposed within the pressure vessel, substantially enclosing the heating means and the reaction zone to define a black body cavity, the heat shield reflecting radiant energy toward the reaction zone. The fluid-wall reactor of the invention may be used in virtually any high temperature chemical reaction, many of which reactions have been previously regarded as impractical or only theoretically possible. Among the reactions which may be carried out in the fluid-wall reactor of the invention as the dissociation of hydrocarbons and hydrocarbonaceous materials, such as coal and various petroleum fractions, into hydrogen and carbon black; the steam reforming of coal, petroleum fractions, oil shale, tar sands, lignite, and any carbonaceous or hydrocarbonaceous feedstock into synthesis gas mixtures; the partial dissociation of hydrocarbons and hydrocarbonaceous materials into lower molecular weight compounds; the partial pyrolysis of saturated hydrocarbons into unsaturated hydrocarbons, such as ethylene, propylene and acetylene; the conversion of organic waste materials, such as sewage sludge, into a fuel gas; the complete or partial desulfurization of sulfur-containing hydrocarbonaceous feedstocks; and the reduction of mineral ores with hydrogen, carbon, synthesis gas, or other reducing agent.
Inventors
- 👤 Edwin Matovich
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 17:32
CPC Classifications
C; C22; C22B; C22B5/00; C22B5/02; B; B01; B01J; B01J12/00; B01J12/005; C01; C01B; C01B3/00; C01B3/02; C01B3/32; C01B3/34; C01B3/342; C01B32/00; C01B32/70; C01B32/90; C09; C09C; C09C1/00; C09C1/44; C09C1/48; C09K; C09K3/00; C09K3/14; C09K3/1436; C10; C10G; C10G15/00; C10G15/08; C10G32/00; C10G32/02; C10G32/04; C10J; C10J3/00; C10J3/46; C10J3/466; C10J3/48; C10J3/50; C10J3/506; C10J3/72; C10J3/723; C10J3/74; C10J3/76; C10J3/78; C21; C21B; C21B13/00; C21B13/04; C01P; C01P2004/00; C01P2004/20; C01P2004/30; C01P2004/32; C01P2006/00; C01P2006/60; C10J2300/00; C10J2300/09; C10J2300/0903; C10J2300/0906; C10J2300/0913; C10J2300/093; C10J2300/0946; C10J2300/0953; C10J2300/0959; C10J2300/0973; C10J2300/0976; C10J2300/12; C10J2300/1246; C10J2300/1269; Y; Y02; Y02P; Y02P10/00; Y02P10/10; Y02P10/134; Y02P10/20
Claims Analysis
Total Claims: 40
Claim 1
Independent Claim
524 words
In a high temperature reactor wherein substantially all of the heat is supplied by radiation coupling, comprising (a) a reactor tube having an inlet end and an outlet end, the interior of the tube defining a reactor chamber, the reactor tube being made of a porous refractory material capable of emitting sufficient radiant energy to raise the temperature of reactants within the reactor tube to a level required to initiate and sustain the desired chemical reaction, the pores of the refractory material being of such diameter as to permit a uniform flow of sufficient inert fluid which is substantially transparent to radiant energy through the tube wall to constitute a protective blanket for the radially inward surface of the reactor tube; (b) a fluid-tight, tubular pressure vessel enclosing the reactor tube to define an inert fluid plenum between the reactor tube and the pressure vessel, the inlet and outlet ends of the reactor tube being sealed from the plenum; the pressure vessel having an inlet for admitting the inert fluid which is directed under pressure into the plenum and through the porous tube wall into the reactor chamber; (c) means for introducing at least one reactant into the reactor chamber through the inlet end of the reactor tube, the reactants being directed in a predetermined path axially of the reactor tube and being confined by the protective blanket substantially centrally within the reactor chamber and out of contact with the inner wall of the reactor tube; (d) electrical means disposed within the plenum and spaced radially outwardly of the reactor tube for heating the reactor tube to the temperature level at which it emits sufficient radiant energy to initiate and sustain the desired chemical reaction, the radiant energy being directed centrally therewithin substantially coincident with at least a portion of the path of the reactants; and (e) a circumferential heat shield disposed within the pressure vessel and radially outwardly of the heating means, the heat shield reflecting radiant energy toward the reactor tube; the improvement in combination therewith comprising: (i) a reactor-tube assembly, including (i.1) the reactor tube of paragraph (a) of the preamble, the reactor tube being made of a porous fabric of a fibrous, refractory material; (i.2) a first support ring having an opening passing therethrough, the first support ring being secured to the inlet end of the reactor tube with the opening of the support ring generally coaxial with the opening in the inlet end of the reactor tube so that the opening of the first support ring communicates with the interior of the reactor tube through the inlet-end opening; and (i.3) a second support ring having an opening passing therethrough, the second support ring being secured to the outlet end of the reactor tube with the opening of the support ring generally coaxial with the opening in the outlet end of the reactor tube so that the opening of the second support ring communicates with the interior of the reactor tube through the outlet-end opening; and (ii) means for attaching the first and the second support rings to the pressure vessel to position the reactor tube within the pressure vessel.
Claim 2
Dependent Claim
524 words
In a high temperature reactor wherein substantially all of the heat is supplied by radiation coupling, comprising (a) a reactor tube having an inlet end and an outlet end, the interior of the tube defining a reactor chamber, the reactor tube being made of a porous refractory material capable of emitting sufficient radiant energy to raise the temperature of reactants within the reactor tube to a level required to initiate and sustain the desired chemical reaction, the pores of the refractory material being of such diameter as to permit a uniform flow of sufficient inert fluid which is substantially transparent to radiant energy through the tube wall to constitute a protective blanket for the radially inward surface of the reactor tube; (b) a fluid-tight, tubular pressure vessel enclosing the reactor tube to define an inert fluid plenum between the reactor tube and the pressure vessel, the inlet and outlet ends of the reactor tube being sealed from the plenum; the pressure vessel having an inlet for admitting the inert fluid which is directed under pressure into the plenum and through the porous tube wall into the reactor chamber; (c) means for introducing at least one reactant into the reactor chamber through the inlet end of the reactor tube, the reactants being directed in a predetermined path axially of the reactor tube and being confined by the protective blanket substantially centrally within the reactor chamber and out of contact with the inner wall of the reactor tube; (d) electrical means disposed within the plenum and spaced radially outwardly of the reactor tube for heating the reactor tube to the temperature level at which it emits sufficient radiant energy to initiate and sustain the desired chemical reaction, the radiant energy being directed centrally therewithin substantially coincident with at least a portion of the path of the reactants; and (e) a circumferential heat shield disposed within the pressure vessel and radially outwardly of the heating means, the heat shield reflecting radiant energy toward the reactor tube; the improvement in combination therewith comprising: (i) a reactor-tube assembly, including (i.1) the reactor tube of paragraph (a) of the preamble, the reactor tube being made of a porous fabric of a fibrous, refractory material; (i.2) a first support ring having an opening passing therethrough, the first support ring being secured to the inlet end of the reactor tube with the opening of the support ring generally coaxial with the opening in the inlet end of the reactor tube so that the opening of the first support ring communicates with the interior of the reactor tube through the inlet-end opening; and (i.3) a second support ring having an opening passing therethrough, the second support ring being secured to the outlet end of the reactor tube with the opening of the support ring generally coaxial with the opening in the outlet end of the reactor tube so that the opening of the second support ring communicates with the interior of the reactor tube through the outlet-end opening; and (ii) means for attaching the first and the second support rings to the pressure vessel to position the reactor tube within the pressure vessel.
Claim 3
Dependent Claim
57 words
The high temperature reactor according to claim 1 in which the fibrous fabric of the reactor tube is stiffened to as to be capable of withstanding without collapsing a fluid pressure differential between the radially outward surface and the radially inward surface of the reactor tube resulting from the flow of inert fluid through the tube wall.
Claim 4
Dependent Claim
17 words
A fluid-wall reactor according to claim 1, in which the fibrous refractory material is graphite or carbon.
Claim 5
Dependent Claim
20 words
A fuid-wall reactor according to claim 1, further including means for applying an axial tensile force to the reactor tube.
Claim 6
Dependent Claim
15 words
A fluid-wall reactor according to claim 1, further including means for cooling the pressure vessel.
Claim 7
Dependent Claim
69 words
A fluid-wall reactor according to claim 1, in which a portion of the interior of the reaction tube between the inlet end of the tube and the reaction zone defines a prereaction zone into which the inert fluid is directed to form a protective blanket which assists in confining the reactants substantially centrally within the reaction zone and out of contact with the inner wall of the reactor tube.
Claim 8
Dependent Claim
87 words
A fluid-wall according to claim 1, in which means for introducing a solid reactant into the reaction zone of the reactor tube includes a helical feed screw rotatably mounted within an elongated tubular housing, drive means for rotating the feed screw, a hopper for introducing a crushed, solid reactant into the housing, means for introducing a pressure sealing fluid into the housing at a point downstream from the hopper, and outlet means for discharging the reactant and the sealing fluid from the housing into the reactor inlet.
Claim 9
Dependent Claim
18 words
A fluid-wall reactor according to claim 1, in which the heat shield is made of a graphitic material.
Claim 10
Dependent Claim
23 words
A fluid-wall reactor according to claim 1, further including reaction product cooling means disposed adjacent to the outlet end of the reactor tube.
Claim 11
Dependent Claim
96 words
A fluid-wall reactor according to claim 1 in which the means for attaching the first and the second support rings to the pressure vessel includes a tubular bellows disposed within an inlet assembly section of the pressure vessel, an inlet end of the bellow being secured in a fluid-tight manner to the inlet assembly section and an outlet end of the bellows being secured to the first support ring to form a fluid-tight connection to the inlet end of the reactor tube, the bellows being deformable to accommodate axial expansion and contraction of the reactor tube.
Claim 12
Dependent Claim
40 words
A fluid-wall reactor according to claim 1, including means for depositing a refractory coating upon portions of the fibrous refractory material of the reactor tube which are disposed within the black body cavity to increase the rigidity of the fabric.
Claim 13
Dependent Claim
73 words
A fluid-wall reactor according to claim 11, in which the refractory coating depositing means includes sensors to determine the pressure differential between the plenum and the reaction zone, metering means for dispensing a refractory deposition agent into the inert gas stream, and reactor tube outlet closure means, the inert gas stream containing the deposition agent being directed into the reaction zone and radially outwardly through the tube wall into the inert fluid plenum.
Claim 14
Dependent Claim
31 words
A fluid-wall reactor according to claim 1, further including means for enlarging the diameter of the pores in the fabric to increase the flow of inert fluid through the tube wall.
Claim 15
Dependent Claim
45 words
A fluid-wall reactor according to claim 13, in which the means for enlarging the diameter of the pores includes sensors to determine the pressure differential between the plenum and the reaction zone and metering means for dispensing an etching agent into the inert gas stream.
Claim 16
Dependent Claim
31 words
A fluid-wall reactor according to claim 1, in which portions of the fibrous refractory material which are heated and exposed to the inert fluid have a coating of a refractory oxide.
Claim 17
Dependent Claim
29 words
A fluid-wall reactor according to claim 15, in which the refractory oxide is thorium oxide, magnesium oxide, zinc oxide, aluminum oxide, zirconium oxide or two or more mixtures thereof.
Claim 18
Dependent Claim
25 words
A fluid-wall reactor according to claim 1, in which the electrical means includes a plurality of electrically resistive heating elements spaced circumferentially about the tube.
Claim 19
Dependent Claim
24 words
A fluid-wall reactor according to claim 17, in which each electrically resistive heating element is made of a fabric of a fibrous refractory material.
Claim 20
Dependent Claim
17 words
A fluid-wall reactor according to claim 19, in which the fibrous refractory material is graphite or carbon.
Claim 21
Dependent Claim
31 words
A fluid-wall reactor according to claim 1, further including means for reducing the diameter of the pores in the fabric to decrease the flow of inert fluid through the tube wall.
Claim 22
Dependent Claim
46 words
A fluid-wall reactor according to claim 20, in which the means for reducing the diameter of the pores includes sensors to determine the pressure differential between the plenum and the reaction zone and metering means for dispensing a refractory deposition agent into the inert gas stream.
Claim 23
Dependent Claim
17 words
A fluid-wall reactor according to claim 21, in which the refractory deposition agent is a carbonaceous gas.
Claim 24
Dependent Claim
18 words
A fluid-wall reactor according to claim 21, in which the refractory deposition agent is a volatile metal-containing compound.
Claim 25
Dependent Claim
64 words
A fluid-wall reactor according to claim 1, further including means for introducing a radiant energy absorptive target into the reactor chamber coincident with at least one point along the path of the reactants which are transparent to radiant energy, sufficient radiant energy being absorbed by the target to raise the temperature of the reactants to a level required to initiate the desired chemical reaction.
Claim 26
Dependent Claim
14 words
A fluid-wall reactor according to claim 24, in which the target is a liquid.
Claim 27
Dependent Claim
29 words
A fluid-wall reactor according to claim 24, in which the target is a gas which exhibits absorption in the electromagnetic spectrum from about 100 microns to about 0.01 microns.
Claim 28
Dependent Claim
38 words
A fluid-wall reactor according to claim 24, in which the target is finely divided carbon powder which is introduced through the inlet end of the reactor tube along a predetermined path coincident with the path of the reactants.
Claim 29
Dependent Claim
72 words
A fluid-wall reactor according to claim 1, in which a means for introducing a liquid reactant into the reaction zone of the reactor tube includes a fogging nozzle disposed within the reactor tube adjacent an inlet of the reaction zone, the liquid reactant and an atomizing gas being directed under pressure and mixed within the nozzle, the liquid reactant being dispersed from the nozzle outlet as a fog which absorbs radiant energy.
Claim 30
Dependent Claim
40 words
A fluid-wall reactor according to claim 28, in which the fogging nozzle includes a tubular shroud secured to and disposed radially outwardly of the nozzle, the axis of the shroud being substantially parallel to the axis of the reactor tube.
Claim 31
Dependent Claim
26 words
A fluid-wall reactor according to claim 28, including a plurality of fogging nozzles disposed within the reactor tube adjacent the inlet end of the reactor zone.
Claim 32
Dependent Claim
48 words
A fluid-wall reactor according to claim 28, in which the means for introducing a liquid reactant into the reaction zone further includes means for introducing a sweep gas into the inlet end of the reactor tube, the sweep gas directing the liquid reactant fog towards the reaction zone.
Claim 33
Dependent Claim
357 words
In combination with a high temperature reactor wherein substantially all of the heat is supplied by radiation coupling, comprising (1) a reactor tube having an inlet end and an outlet end, the interior of the tube defining a reactor chamber, the reactor tube being made of a porous refractory material capable of emitting sufficient radiant energy to raise the temperature of reactants within the reactor tube to a level required to initiate and sustain the desired chemical reaction; the pores of the refractory material being of such diameter as to permit a uniform flow of sufficient inert fluid which is substantially transparent to radiant energy through the tube wall to constitute a protective blanket for the radially inward surface of the reactor tube; (2) a fluid-tight, tubular pressure vessel enclosing the reactor tube to define an inert fluid plenum between the reactor tube and the pressure vessel, the inlet and outlet ends of the reactor tube being sealed from the plenum; the pressure vessel having an inlet for admitting the inert fluid which is directed under pressure into the plenum and through the porous tube wall into the reactor chamber; (3) means for introducing at least one reactant into the reactor chamber through the inlet end of the reactor tube, the reactants being directed in a predetermined path axially of the reactor tube and being confined by the protective blanket substantially centrally within the reactor chamber and out of contact with the inner wall of the reactor tube; (4) electrical means disposed within the plenum and spaced radially outwardly of the reactor tube for heating the reactor tube to the temperature level at which it emits sufficient radiant energy to initiate and sustain the desired chemical reaction, the radiant energy being directed centrally therewithin substantially coincident with at least a portion of the path of the reactants; and (5) a circumferential heat shield disposed within the pressure vessel and radially outwardly of the heating means, the heat shield reflecting radiant energy toward the reactor tube; means for enlarging the diameter of the pores in the tube wall to increase the flow of inert fluid through the wall.
Claim 34
Dependent Claim
357 words
In combination with a high temperature reactor wherein substantially all of the heat is supplied by radiation coupling, comprising (1) a reactor tube having an inlet end and an outlet end, the interior of the tube defining a reactor chamber, the reactor tube being made of a porous refractory material capable of emitting sufficient radiant energy to raise the temperature of reactants within the reactor tube to a level required to initiate and sustain the desired chemical reaction; the pores of the refractory material being of such diameter as to permit a uniform flow of sufficient inert fluid which is substantially transparent to radiant energy through the tube wall to constitute a protective blanket for the radially inward surface of the reactor tube; (2) a fluid-tight, tubular pressure vessel enclosing the reactor tube to define an inert fluid plenum between the reactor tube and the pressure vessel, the inlet and outlet ends of the reactor tube being sealed from the plenum; the pressure vessel having an inlet for admitting the inert fluid which is directed under pressure into the plenum and through the porous tube wall into the reactor chamber; (3) means for introducing at least one reactant into the reactor chamber through the inlet end of the reactor tube, the reactants being directed in a predetermined path axially of the reactor tube and being confined by the protective blanket substantially centrally within the reactor chamber and out of contact with the inner wall of the reactor tube; (4) electrical means disposed within the plenum and spaced radially outwardly of the reactor tube for heating the reactor tube to the temperature level at which it emits sufficient radiant energy to initiate and sustain the desired chemical reaction, the radiant energy being directed centrally therewithin substantially coincident with at least a portion of the path of the reactants; and (5) a circumferential heat shield disposed within the pressure vessel and radially outwardly of the heating means, the heat shield reflecting radiant energy toward the reactor tube; means for enlarging the diameter of the pores in the tube wall to increase the flow of inert fluid through the wall.
Claim 35
Dependent Claim
45 words
A fluid-wall reactor according to claim 32, in which the means for enlarging the diameter of the pores includes sensors to determine the pressure differential between the plenum and the reaction zone and metering means for dispensing an etching agent into the inert gas stream.
Claim 36
Dependent Claim
357 words
In combination with a high temperature reactor wherein substantially all of the heat is supplied by radiation coupling, comprising (1) a reactor tube having an inlet end and an outlet end, the interior of the tube defining a reactor chamber, the reactor tube being made of a porous refractory material capable of emitting sufficient radiant energy to raise the temperature of reactants within the reactor tube to a level required to initiate and sustain the desired chemical reaction; the pores of the refractory material being of such diameter as to permit a uniform flow of sufficient inert fluid which is substantially transparent to radiant energy through the tube wall to constitute a protective blanket for the radially inward surface of the reactor tube; (2) a fluid-tight, tubular pressure vessel enclosing the reactor tube to define an inert fluid plenum between the reactor tube and the pressure vessel, the inlet and outlet ends of the reactor tube being sealed from the plenum; the pressure vessel having an inlet for admitting the inert fluid which is directed under pressure into the plenum and through the porous tube wall into the reactor chamber; (3) means for introducing at least one reactant into the reactor chamber through the inlet end of the reactor tube, the reactants being directed in a predetermined path axially of the reactor tube and being confined by the protective blanket substantially centrally within the reactor chamber and out of contact with the inner wall of the reactor tube; (4) electrical means disposed within the plenum and spaced radially outwardly of the reactor tube for heating the reactor tube to the temperature level at which it emits sufficient radiant energy to initiate and sustain the desired chemical reaction, the radiant energy being directed centrally therewithin substantially coincident with at least a portion of the path of the reactants; and (5) a circumferential heat shield disposed within the pressure vessel and radially outwardly of the heating means, the heat shield reflecting radiant energy toward the reactor tube; means for reducing the diameter of the pores in the tube wall to decrease the flow of inert fluid through the wall.
Claim 37
Dependent Claim
357 words
In combination with a high temperature reactor wherein substantially all of the heat is supplied by radiation coupling, comprising (1) a reactor tube having an inlet end and an outlet end, the interior of the tube defining a reactor chamber, the reactor tube being made of a porous refractory material capable of emitting sufficient radiant energy to raise the temperature of reactants within the reactor tube to a level required to initiate and sustain the desired chemical reaction; the pores of the refractory material being of such diameter as to permit a uniform flow of sufficient inert fluid which is substantially transparent to radiant energy through the tube wall to constitute a protective blanket for the radially inward surface of the reactor tube; (2) a fluid-tight, tubular pressure vessel enclosing the reactor tube to define an inert fluid plenum between the reactor tube and the pressure vessel, the inlet and outlet ends of the reactor tube being sealed from the plenum; the pressure vessel having an inlet for admitting the inert fluid which is directed under pressure into the plenum and through the porous tube wall into the reactor chamber; (3) means for introducing at least one reactant into the reactor chamber through the inlet end of the reactor tube, the reactants being directed in a predetermined path axially of the reactor tube and being confined by the protective blanket substantially centrally within the reactor chamber and out of contact with the inner wall of the reactor tube; (4) electrical means disposed within the plenum and spaced radially outwardly of the reactor tube for heating the reactor tube to the temperature level at which it emits sufficient radiant energy to initiate and sustain the desired chemical reaction, the radiant energy being directed centrally therewithin substantially coincident with at least a portion of the path of the reactants; and (5) a circumferential heat shield disposed within the pressure vessel and radially outwardly of the heating means, the heat shield reflecting radiant energy toward the reactor tube; means for reducing the diameter of the pores in the tube wall to decrease the flow of inert fluid through the wall.
Claim 38
Dependent Claim
46 words
A fluid-wall reactor according to claim 34, in which the means for reducing the diameter of the pores includes sensors to determine the pressure differential between the plenum and the reaction zone and metering means for dispensing a refractory deposition agent into the inert gas stream.
Claim 39
Dependent Claim
17 words
a fluid-wall reactor according to claim 35, in which the refractory deposition agent is a carbonaceous gas.
Claim 40
Dependent Claim
18 words
A fluid-wall reactor according to claim 35, in which the refractory deposition agent is a volatile metal-containing compound.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1983-04-22 | 1983-10-22 | 1984-04-22 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-04-22 | 1987-10-22 | 1988-04-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-04-22 | 1991-10-22 | 1992-04-22 | $7700.00 | Window Closed / Lapsed |