Patent Application
20250114766
In view of the problems associated with increasing global warming and the reduced availability of fossil fuels, it is becoming increasingly important to find practicable and flexible solutions for converting waste products, such as waste gases, into higher-value hydrocarbon compounds.
A readily and widely available starting product for such conversion is CO2 in particular. However, in order to render the carbon from CO2 available for the production of higher-value hydrocarbons, it must first be “activated”, for example by converting CO2 into carbon monoxide (CO).
With regard to the conversion of CO2 into CO, various reactors and processes are discussed in the literature. DE 10 2017 120 817, for example, describes a reactor, in which a so-called rWGS reaction (reverse water gas shift reaction) can be advantageously carried out. However, the endothermic rWGS reaction requires high temperatures (typically above 600° C.), also in order to avoid or to minimize disruptive side reactions such as a methane or soot formation. In order to achieve such high temperatures, a considerable amount of energy must be introduced into the system (and/or the energy loss, especially the heat loss, must be minimized). It is also advantageous to use the energy introduced into the system for other (subsequent) processes, i.e. not just the rWGS reaction. Other endothermic high-temperature processes such as an ammonia synthesis also require such thermal/energetic optimization and corresponding reactor modules and reactor systems.
WO 2021/063796 describes reactors for an “on demand” synthesis for a methanol cracking and the rWGS. Here, the reactant gases are passed over structured catalyst zones in which the catalytically active material is deposited on the surfaces of these zones and a corresponding structure of an electrically conductive material is also applied in order to heat the catalyst layer via a resistance heater.
Reactor systems for such conversions, which can be scaled up or down depending on local requirements, and which ideally can be transported from site to site, for example in transportable support frames or containers, are of particular interest when fossil associated and surplus gases are to be processed or converted.
In light of the prior art, one object of the present invention is, among other considerations, to provide reactors for chemical reactions in which easily scalable approaches can be run.
Another object of the present invention is to optimize the heat balance in endothermic (or only slightly exothermic) reactions.
According to a first aspect, the problems underlying the invention are at least partially solved by a plate element for a reactor module for carrying out endothermic reactions, wherein the plate element comprises at least:
In accordance with the present invention, “materially connected” means that a fluid can flow, in principle, unhindered into the connected elements, for example from a channel into a zone or vice versa.
In accordance with the present invention, “thermally connected” or “in thermal communication” means that thermal energy can be transferred by convection, radiation and heat conduction, for example from a heating element to a reaction zone or from a heating element to a reactant fluid.
In embodiments, the at least one heating element in material communication with at least one first reactant fluid channel and/or at least one second reactant fluid channel is thermally connected to the reaction zone, said heating element being spaced from said reaction zone by a minimum common distance of not more than 10 mm, preferably not more than 5 mm, or the end of the heating element furthest downstream in the flow direction is spaced not more than 25 mm, preferably not more than 15 mm, from the reaction zone in the flow direction, or both.
In embodiments, “being in thermal communication” means that heat is transferred by conduction via a plate element from at least one heating element to a reaction zone, or that heat is transferred via heated reactant fluid from a heating element to reaction zone, or both.
In embodiments, “being in thermal communication” means that two regions of a plate element (or a reactor module or of a reactor system) are thermally conductively connected to each other in such a way that the thermal conductivity is from 5 W/mK to 20 W/mK at 20° C., preferably from 8 W/mK to 16 W/mK at 20° C., and more preferably from 10 W/mK to 15 W/mK at 20° C., and/or from 10 W/mK to 50 W/mK at 800° C., preferably from 15 W/mK to 40 W/mK at 800° C., and more preferably from 20 W/mk to 35 W/mK at 800° C. These thermal conductivities in particular allow for an efficient heating of the catalyst even by heating elements not located in the catalyst bed.
This “direct” heating of both the (all) reactant fluids and the reaction zone is advantageous compared to the examples mentioned in the prior art, since lower temperature gradients occur in the reaction zone, and here in particular in the catalyst, the reactant fluids are uniformly brought to the high temperature required for endothermic reaction and suffer only a slight, if any, heat loss in the catalyst.
In accordance with the present invention, “high temperatures” means temperatures from 400° C. to 1500° C., preferably from 500° C. to 1200° C., more preferably from 600° C. to 1100° C., and particularly preferably from 700° C. to 1000° C.
In embodiments of the invention (as illustrated in
In accordance with the present invention, “direct physical contact” means that the reactant fluid comes into direct physical contact with at least a part of the heating element, so that the reactant fluid is deflected or redirected by this part of the heating element and/or that a change in the flow properties occurs due to a change in cross-section in the sense of Hagen Poiseuille's law.
In embodiments of the invention (as illustrated in
In embodiments of the invention, the heating element comprises a resistance wire surrounded by a ceramic sheath, the wire preferably being completely surrounded by the ceramic sheath.
In embodiments of the invention, the heating element is connected to the plate element with one element flush with the other element (“form fit”) via at least one high-temperature resistant, preferably flexible, material.
In embodiments of the invention, the high-temperature resistant, preferably flexible, material comprises a fiber material or a felt material, preferably selected from aluminum, zirconium or silicon oxides/hydroxides, or combinations thereof. In embodiments, the high-temperature resistant, preferably flexible, material comprises any or all of these materials.
In accordance with the present invention, “form-fit” means that an outer surface of the heating element is connected to a surface of the plate element via the high-temperature resistant material by interlocking surface structures, so that preferably all three components (the heating element, the high-temperature resistant material and the plate element) are fixed against each other, preferably even in the absence of or an interruption of applied force.
In accordance with the present invention, “high-temperature resistant” means that no physical or chemical changes of the materials occur, which impair the functionality of the plate elements or reactor modules, in particular not at temperatures up to 900° C., up to 1100° C. or up to 1500° C.
In accordance with the present invention, “flexible” means that the material is pliable and elastic, in particular elastic in all three spatial directions.
In embodiments, the plate element comprises at least one electrical connection for operating a heating element, preferably a plurality of such electrical connections, wherein the electrical connection(s) is/are preferably arranged substantially perpendicular to the direction of flow of the reactant and product fluids, wherein preferably all electrical connections are arranged substantially perpendicular to the direction of flow of the reactant and product fluids.
This arrangement of the electrical feedthrough essentially in an orthogonal manner or slightly against the direction of flow of the gases to be heated (i.e. “laterally” protruding with vertically “upright” arranged plate elements) is associated with the advantage that the plates and in particular the channels can be better sealed against each other. Therein, the effect of the static pressure of the flow is at a maximum, but not the dynamic pressure along the feedthrough.
In embodiments of the invention, the at least one heating element is arranged essentially parallel to the reaction zone (see
In embodiments of the invention, the at least one heating element is arranged substantially perpendicular to the reaction zone.
For the purposes of the present invention, “substantially perpendicular” means an angle of 85° to 95° and “substantially parallel” means an angle of 175° to 185°.
In preferred embodiments, the at least one heating element in material communication with at least one first reactant fluid channel and/or with at least one second reactant fluid channel is thermally conductively connected to the reaction zone, and this heating element is spaced from this reaction zone by a minimum common distance of not more than 10 mm, preferably not more than 5 mm, and/or the heating element is spaced from the reaction zone in the direction of flow by not more than 35 mm, preferably by not more than 25 mm, and more preferably by not more than 15 mm.
In embodiments, the end of a heating element furthest downstream in the direction of flow is no more than 45 mm, preferably 25 mm, and more preferably no more than 15 mm from the start of the reaction zone in the direction of flow.
In embodiments, “being in thermal communication” comprises heat transfer by heat conduction from the heating element to the reaction zone via a plate element, or via the reactant fluid heated by a heating element, or both.
In preferred embodiments, the thermal conductivity of the plate element (averaged over the entire plate element) is from 5 W/mK to 20 W/mK at 20° C., preferably from 8 W/mK to 16 W/mK at 20° C., and more preferably from 10 W/mK to 15 W/mK at 20° C., and/or from 10 W/mK to 50 W/mK at 800° C., preferably from 15 W/mK to 40 W/mK at 800° C., and more preferably from 20 W/mK to 35 W/mK at 800° C. In particular, these thermal conductivities allow for an efficient heating of the catalyst even via heating elements not located in the catalyst bed.
In accordance with the present invention, the “least common distance” is the smallest length that can be measured from any part of the heating element located at the outer periphery to any part of the outer periphery of the reaction zone. Herein, a small distance is synonymous with “good heat transfer”, since the heat input from the heating element to the reaction zone is significantly reduced or the heat losses increase as the distance increases.
According to a second aspect, the problems underlying the invention are at least partially solved by a reactor module for carrying out endothermic reactions at high temperatures, wherein the reaction module comprises at least two plate elements pressed against each other and sealed against each other as described above or as described throughout the present document, preferably at least three or four plate elements, and more preferably exactly three or four plate elements, wherein at least two plate elements are different from each other, in particular with respect to their geometry and/or structure.
In embodiments of the invention, at least two of the plate elements which are pressed against each other and sealed against each other are materially connected to each other by at least two channels common to all plate elements for supplying the reactant fluid, and at least one channel common to all plate elements for discharging product fluid.
In embodiments, at least one heating element, preferably the majority of the heating elements located in the reactor module, and more preferably all heating elements, are each in direct physical contact with the first reactant fluid or the second reactant fluid, or both.
In accordance with the present invention, a “majority” of heating elements is at least half of all heating elements.
In embodiments, at least one heating element, or preferably the majority of the heating elements located in the reactor module, has/have a reactant fluid flowing around and/or through the same in a reactant fluid channel or in a mixing zone, or both.
According to a third aspect, the problems underlying the invention are at least partially solved by a reactor system comprising at least three, preferably at least six, and more preferably at least nine substantially identical reactor modules, as described above or throughout the present disclosure, which are connected in parallel next to each other.
In accordance with the present invention, “substantially identical in construction” means that the reactor modules may have minor deviations, in particular due to manufacturing tolerances, but are the same in terms of function, throughput and other key reactor figures, apart from tolerances.
In embodiments, the heater is preferably operated with rotating current (i.e. three phases). In this context, reactor modules connected in parallel in multiples of “three” within a reactor system are particularly efficient and thus preferred.
In embodiments of the invention, the reactor system comprises a pressure-resistant container in which the reactor modules are arranged materially separate from the environment (i.e. no mass transfer with the environment can take place). Preferably, the reactor modules are arranged essentially perpendicular to the base (i.e. the floor on which the reactor system is located).
In embodiments of the invention, all reactor modules comprise at least two common channels for supplying reactant fluid and at least one common channel for discharging product fluid.
In embodiments of the invention, the pressure-resistant vessel is charged with a reaction gas used in the reactor system, in particular with a water vapor stream or a hydrogen stream, or a mixture of both.
In embodiments of the invention, the pressure-resistant container has a heating system.
According to a fourth aspect, the problems underlying the invention are at least partially solved by a method for carrying out endothermic reactions, in particular at high temperatures, using a reactor system as described above and as described throughout the disclosure.
In embodiments of the invention, the reaction is selected from reforming, in particular methane reforming, ammonia synthesis, ammonia cracking, methanol cracking or reverse water gas conversion (rWGS).
In embodiments of the invention, the first and second reactant fluids are in thermal contact, preferably also in material contact, with different, separately controllable heating elements, and wherein the energy input into the reactant fluid stream via the respective heating element is different.
In embodiments of the invention, the first and second reactant fluids are different from each other, wherein preferably the first reactant fluid substantially contains CO2, and the second reactant fluid is a H2-containing fluid.
In embodiments, the pressure-resistant vessel of the reactor system is charged with a reaction gas used in the reactor system, in particular with a water vapor stream or a hydrogen stream, or a mixture of both, wherein the gas stream preferably reaches the catalyst located in the reaction chamber via defined leakages at the feedthrough or feedthroughs to one or more heating elements.
In embodiments, the pressure outside the reactor module and inside the pressure-resistant vessel of the reactor system is greater than in the reaction chambers of the reactor module.
A “plate element” in the sense of the present invention is a three-dimensional body which is defined by two opposing, preferably differently structured cuboidal or square surfaces which are spaced apart from one another, the plate element having a maximum thickness but not necessarily a constant thickness due to the structuring.
The maximum thickness of a plate element is significantly smaller in relation to the lengths of the surfaces, preferably the thickness is less than 1/1000 of the maximum length, preferably less than 1/100.
The plate elements are preferably rectangular, i.e. these are longer (higher) than wide.
In embodiments, the length of a plate element is from 50 cm to 5 m, preferably from 1 m to 3 m, and more preferably from 1 m to 2 m.
In embodiments, the width of a plate element is from 5 cm to 100 cm, preferably from 10 cm to 60 cm, and more preferably from 20 cm to 50 cm.
In embodiments, the thickness of a plate element is from 1 mm to 50 mm, preferably from 2 mm to 30 mm, and more preferably from 3 mm to 20 mm.
In embodiments, the plate element comprises, preferably the plate element consists of, a metal or a metal alloy. Preferably, this alloy is a high-temperature resistant steel. This steel is preferably chemically stable, and in particular resistant to the incorporation of carbon (metal dusting).
Suitable exemplary steels are known as Alloy 800 H/HT, Inconel CA 602, Inconel 693 or under the DIN designations 2.4633 or 1.4876, furthermore Alloy 601, Alloy 690, Alloy 693 and Alloy 699 XA. The steel can also be at least partially provided with an alitization, a water glass coating or a tin coating in order to increase the resistance to metal dusting/soot formation.
A plate element according to the invention has at least three micro- or milli-structured channels which serve to feed or discharge reactant fluids or product fluids into/from a reaction zone.
The characteristic dimension of “micro- or milli-structured” channels in the sense of the invention refers to the “largest cross-sectional length” with which the cross-section of a channel can be described. These channels can have a circular diameter (in which case the largest cross-sectional length is the diameter) or be oval or ovoid, in which case there are at least two characteristic cross-sectional lengths, the larger of which is the “largest cross-sectional length”. In the case of square ducts or ducts with a cuboid cross-section, the largest cross-sectional length is the diagonal.
In embodiments of the present invention, the channels may be incorporated into the plate elements, e.g. milled in. Flow-through cross-sections in the sense of tubes (with an inner diameter and an outer diameter), as are typically used in tube bundle reactors, are preferably not “channels” in the sense of the present invention.
Thus, the channels in the plate elements in the sense of the present invention are not tubes as used in tube bundle reactors.
In embodiments, this “largest cross-sectional length” of a “micro- or milli-structured” channel ranges from 500 μm to 100 mm, preferably from 800 μm to 50 mm, particular preferably from 1 mm to 40 mm, and more preferably from 2 mm to 20 mm.
In embodiments, the channels are arranged side by side and/or on top of each other, and run substantially parallel to each other. The presence of a plurality of channels next to each other (or on top of each other) increases the overall heat transfer within the plate element as well as between the plate elements.
In embodiments, the channels are arranged in and/or between the plate elements according to the invention. In embodiments, the channels are arranged between two plates according to the invention, i.e. the channels are formed by connecting a first plate according to the invention with a second plate according to the invention to form a pair of plates.
The reactant fluid channel and the product fluid channel may be of the same or different geometry/design.
In addition to these reactant fluid and product fluid channels (preferably arranged vertically, i.e. in “upright” plates), the plate elements, in particular when these are joined together to form a reactor module or a reactor system, preferably also contain at least two reactant fluid feed devices, each of which is connected to a reactor module or a reactor system, preferably also at least two reactant fluid feed devices each of which is connected to a reactant source, as well as at least one product fluid discharge device which collects the product fluid and feeds it to further processing (detection, separation, subsequent reaction, in particular Fischer-Tropsch reaction or methanol synthesis).
Both the reactant fluid feed devices and the product fluid discharge device are preferably arranged perpendicular to the micro- and milli-structured reactant fluid or product fluid channels, and extend parallel to the bottom (see “end plate” (1.10) in
Preferably, both reactant fluid supply devices and product fluid discharge devices are arranged via through-holes at a first and/or second end of a plate according to the invention.
The sealing of both the reactant fluid supply device and the product fluid discharge device against unwanted or uncontrolled leakage of reactant fluid and/or product fluid can be achieved by temperature-resistant O-rings (temperatures up to approx. 300° C. are possible), by mica seals or by weld ring seals. Similarly, the plates can also be sealed against each other as such.
In embodiments, a plate element according to the invention has both reactant fluid channels and product fluid channels on one surface.
In embodiments, a plate element according to the invention exclusively has reactant fluid channels, whereas another plate element exclusively has product fluid channels, or a plate element has exclusively reactant fluid channels or product fluid channels.
In embodiments, in particular when the reaction to be carried out in the plate element is a rWGS reaction, at least one reactant fluid is a fluid comprising or consisting essentially of CO2. At least one further reactant fluid is then a fluid comprising or consisting of H2. The CO2 reactant fluid and the H2 reactant fluid are fed to the reaction zone in separate, distinct reactant fluid channels and are not mixed until they enter this zone, which comprises a catalyst during operation.
In embodiments, the product fluid comprises CO. Furthermore, the product fluid may comprise one or more fluid(s) selected from CO2, H2, CH4 or mixtures thereof.
A plate element according to the invention has at least one reaction zone which can be charged with a catalyst or which is charged with a catalyst, in particular a catalyst fixed-bed charge, during operation. In embodiments, the catalyst is suitable for promoting the conversion of carbon dioxide (CO2) and hydrogen (H2) to carbon monoxide (CO) and water (H2O). This conversion is referred to as a reverse water gas shift (rWGS).
In embodiments, the fixed bed catalyst essentially consists of particles having an average diameter from 500 μm to 5 mm, and preferably from 1 mm to 3 mm.
In embodiments, the reaction zone is essentially arranged on that side of a plate element which is opposite to the side of the plate element which forms the reactant fluid and product fluid channels, optionally in interaction with further plates of a reactor module.
In embodiments, this reaction zone extends over at least 50%, preferably at least 80% of the width on this one side of the plate element, as well as over a maximum of 30% of the total length of the plate element, and preferably over a maximum of 20% of the length.
In embodiments, the reaction zone is arranged substantially parallel to the direction of flow of the reactant and product fluids.
Preferably, the reaction zone has a length (“height” if the plate element, as it is preferred, is arranged “upright” or vertically) of from 5 cm to 50 cm, preferably from 10 cm to 30 cm, and more preferably from 12 cm to 25 cm.
The reaction, in particular an endothermic reaction, and in particular an rWGS reaction, takes place in the reaction zone. The reaction zone is therefore heated to temperatures of at least 650° C., preferably at least 700° C., preferably from 600° C. to 1500° C. or 1100° C., more preferably from 700° C. to 1000° C., particularly preferably from 700° C. to 900° C., and more preferably from 720° C. to 780° C., by means of a thermal connection to the heating elements according to the invention, and to the preheated reactant fluids.
In embodiments, there are no heating elements in the reaction zone itself.
In embodiments, the reaction zone is heated to the temperature required for carrying out an endothermic reaction exclusively via the preheated reactant fluids and by thermal contact with the heating elements also provided for heating the reactant gas.
A plate element according to the invention, in particular plate elements according to the invention in a reactor module, have at least one heating element which is in thermal contact with the at least one first reactant fluid channel or the at least one second reactant fluid channel, as well as the reaction zone.
By “heating element” in the sense of the present invention a device is meant which is suitable for transferring thermal energy from the heating element to the fluids flowing in the reactant fluid channels and into a reaction zone. For this purpose, the heating element must be in thermal contact with the fluids flowing in the reactant fluid channels and the reaction zone. The thermal energy can be transferred via conduction, radiation and convection. Preferably, the reactant fluids are heated to temperatures from 400° C. to 1500° C. or to temperatures from 720° C. to 1100° C., and preferably from 750° C. to 900° C.
The heating element preferably comprises a resistance wire which heats up according to Ohm's law when an electric current flows through it.
The resistance wire is further preferably encased in a ceramic sheath, at least partially, and preferably completely, wherein the cross-section (a diameter or a largest length in the cross-section) is 2 to 8 mm, and preferably 3 to 6 mm.
In embodiments, the length of the heating element is from 5 cm to 40 cm, and preferably from 10 cm to 20 cm. The structure of such a heating element is described by way of example in the U.S. Pat. No. 9,867,232. Preferred heating elements of this type are so-called “flow heaters”.
Preferably, the at least one heating element is connected to the plate element according to the invention in “form-fit” manner and via at least one high-temperature resistant, preferably flexible, material.
In embodiments, the flexible material is a fiber mat that can be compacted by a factor of 2 to 5 without a force from the outside being noticeably transmitted to the ceramic of the heating element.
The high-temperature resistant, preferably flexible, material is preferably selected from Al2O3 and/or mica. Preferably, the high-temperature resistant, flexible material is realized as a fiber mat or a fleece. The thickness of the fiber mat or the fleece is preferably less than 1 mm.
The at least one heating element is at least partially, and preferably completely, enclosed by a high-temperature resistant, preferably flexible, material. This is associated with the advantage that the material can thus also act as a breakdown protection against voltage flashovers in the event of breakage of the ceramic sheath of the resistance wire of the heating element.
Preferably, the high-temperature resistant, preferably flexible material is arranged on both sides, in a parallel arrangement, around one or more heating elements (see
The at least one heating element can furthermore be equipped with at least one support device. The support device extends essentially parallel to the heating element and is in direct material contact with the ceramic of the heating element or consists of the same material (see
The plate element according to the invention also has electrical connections for operating the at least one heating element.
The electrical connections preferably emanate laterally, vertically (i.e. not in the direction of flow of the reactant fluids and product fluids) from the plate element according to the invention, and preferably on the outlet side of the heating element (see
In embodiments, the cross-section of the resistance wire is enlarged towards the area around which the reactant fluid flows to the connections, i.e. the areas around which the reactant fluid does not flow, in order to avoid thermally induced breakage of the resistance wire.
The increase in cross-section is preferably achieved by a thickening wire or by two twisted wires.
As the cross-section of the resistance wire increases, the diameter of the heating element as a whole, including the surrounding ceramic, is increased. Thus, the lead-through from the plate elements can also be adapted to this increased diameter.
In embodiments, the feedthrough is preferably arranged to emanate out of the plate elements in a plane with the heating element, around which the reactant fluid flows. This has the advantage of compensating for a change in length of the resistance wire during current flow/heating and avoiding a voltage flashover.
Preferably, the plate element has slots on the sides through which electrical connections can be made.
Preferably, the at least one heating element (or the majority of heating elements) is arranged substantially parallel to the reaction zone (see
This embodiment is explained in more detail below in
As shown in
The reference signs in
Section (A) in
Finally,
The plate element according to the invention furthermore may comprise at least one heat recuperation zone. In this zone, a heat transfer preferably takes place from the hot product fluid to the reactant fluids guided in a countercurrent.
This recuperation zone is preferably located above the reaction zone, in particular in the case of “standing plates”. This heat recuperation between the product fluid and the reactant fluid is also advantageously increased compared to prior art examples (for example, compared to tubular reactors) by the fact that a particularly good heat exchange can take place in channels of a plate element, as less thermal resistance has to be overcome than, for example, in a tubular bundle reactor, in which the diameter and spacing of the tubes require a turbulent flow in order to maximize the heat transfer coefficients at the wall, or the wall thickness of the tubes must be greater than the thickness of the plate separating the channels. In the channels, the heat transfer coefficient increases reciprocally with reduced height of the channels due to the laminar flow.
In embodiments, in these recuperation zones, a preheating or a heating of the reactant fluids to 400° C. and more, preferably to 600° C. and more, and more preferably to 700° C. and more, is achieved before the reactant gases are brought to the final temperature before entering the reaction zone with the aid of the heating elements according to the invention.
In embodiments, this heat recuperation zone (for the heat exchange between the product fluid and the reactant fluid) is arranged upstream (in the direction of flow of the reactant fluids) of the heating elements, preferably at least 10 cm upstream of the furthest upstream end of the heating element, and more preferably at least 20 cm or 50 cm.
In a further aspect, the present invention relates to a reactor module for carrying out an endothermic high-temperature process, wherein the reactor module comprises at least two plate elements according to the invention as described above and throughout the disclosure, preferably at least three or four plate elements, and more preferably exactly four plate elements.
Preferably, the reactor comprises at least one pair of plate elements, or a stack of plate elements or a stack of pairs of plate elements. To build up such stacks, a first plate element is pressed against a second plate element by means of a circumferential seal comprising, for example, mica. This process is repeated until the desired stack size is reached and a reactor module is built up.
Preferably, the first plate element comprises reactant fluid channels and the second plate element comprises product fluid channels. This has the advantage that the flow of reactant fluid(s) through the heating element is thus ensured. In addition, the unwanted discharge of reactant fluid from the plate stack is prevented.
The sealing of the plates (e.g. via mica) also acts as a compensating element for any different degrees of material expansion that may occur due to temperature gradients occurring in the stack or in the pair of plates.
In embodiments, the seal is “reversible”, i.e. it can be broken without destroying a plate element. This makes it easy to dismantle the stack or the pair of plates for maintenance or repair purposes.
In further embodiments, at least two reactor modules according to the invention are connected in parallel to form a reactor system as described above and throughout the application as a whole, so that the throughput can be scaled up and down as desired-within technically reasonable limits.
Preferably, at least three or at least six or nine reactor modules are connected in parallel.
The reactor system preferably also comprises a pressure-resistant container in which the reactor modules or the stack of plate elements or the pairs of plate elements can be operated without mass transfer with the environment. This is associated with the advantage that the electrical connections for the at least one heating element, which are led out of the plate element, do not have to be completely sealed, and a leaking reactant fluid or leaking reactant fluids can be collected.
The reactor modules are preferably attached via a suspension. A suspension (at the comparatively cool upper end) is advantageous because the hot areas of the plate elements are thus not thermally conductively connected to the outer housing.
In embodiments, the pressure-resistant container is pressurized with a purge gas, in the case of an rWGS with hydrogen. This has the advantage that any reactant fluids that may have escaped from a reactor module can be “flushed” back into the stack. The proportion of the purge gas can be included in the reactant fluid composition if the purge gas participates in the endothermic high-temperature process.
The vessel may be made of stainless steel.
The container may also be equipped with internal heating. This has the advantage that, for example, water vapor which could be present in or added to a reactant fluid does not condense out on the walls of the container.
The container also may comprise feedthroughs for electrical connections. These feedthroughs are flooded with an inert gas, preferably nitrogen. This has the advantage that leaks can be detected, e.g. by means of appropriate sensors, and ignitions at the electrical connections can be avoided.
The variable (scalable) structure of the reactor modules and systems according to the invention with the plate elements as well as the variable stack height, which is defined by the number of plate elements according to the invention, has the advantage that different module sizes of the reactor system according to the invention can be set up quickly and predictably (in respect to throughput).
In embodiments, each plate element according to the invention has the same number of reactant fluid channels and product fluid channels in the reactor according to the invention. Thus, it is possible to obtain a direct correlation of throughput and stack height.
Further according to the invention is a method for carrying out endothermic high-temperature processes using the reactor module or reactor system according to the invention as described above.
Further according to the invention is the use of the reactor according to the invention for carrying out endothermic high-temperature processes, preferably selected from reforming reactions, in particular a methane reforming, an ammonia synthesis, an ammonia cracking, a methanol cracking or a reverse water gas conversion (rWGS), wherein carrying out an rWGS is particularly preferred.
A reactor system according to the invention was constructed from 6 identical reactor modules as shown in
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2021 208 923.2 | Aug 2021 | DE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/072543 | 8/11/2022 | WO |
