CN109954450B

CN109954450B - Wire mount for stackable structural reactor

Info

Publication number: CN109954450B
Application number: CN201910268244.0A
Authority: CN
Inventors: W·A·惠滕伯杰; J·W·惠滕伯杰; B·L·戴维斯
Original assignee: Johnson Matthey PLC
Current assignee: Johnson Matthey PLC
Priority date: 2012-04-02
Filing date: 2013-03-29
Publication date: 2022-06-17
Anticipated expiration: 2033-03-29
Also published as: CN109954450A

Abstract

A wire standoff suitable for use in a tubular reactor, such as a reformer, is described. The wire standoff includes a portion or section located between the outer reactor tube and one or more reactor components within the tube. By placing the wire standoff, the reactor component and the outer tube are prevented from directly contacting each other. The wire standoff may be secured at one of its ends to the reactor component or a gasket located between stacked reactor components. Preventing the reactor components from contacting the outer tube facilitates fluid flow through the reactor and may increase heat transfer and reactor efficiency for performing catalytic reactions.

Description

Wire mount for stackable structural reactor

The present application is a divisional application of an invention patent application entitled "wire mount for a stackable structural reactor", having international application date of 2013, 3 and 29, international application number of PCT/US2013/034570, national application number of 201380028708.1.

Technical Field

The present invention relates to an improved stackable structural reactor with improved efficiency and productivity, and in particular to an improved stackable structural reactor with one or more wire seating devices for improving heat transfer and reactor efficiency.

Background

Reactor components for performing catalytic reactions, such as reactor components for producing syngas and hydrogen, may generally contact reactor tubes exposed to a heat source (e.g., a boiler) to support the reactions. Conversely, other types of reactions, such as exothermic reactions, require a cooling source, such as a cooling jacket. The reactor tube may be loaded with various arrangements of components, such as foil supports or structured catalysts in the form of fan structures, fins, foams, coils, or monolithic columns. In some examples, the reactor component may be expandable, such as a component formed from a foil, e.g., a fan-shaped structure.

To improve heat transfer and fluid flow through the reactor, the fit of the foil-supported catalyst may be improved. In a reactor tube, expandable catalyst coated reactor components may be placed to increase heat transfer, such as near the reactor wall exposed to a heating or cooling source. Accordingly, it is desirable to mate the reactor with accessories to promote increased heat transfer and reactor efficiency, such as features that create fluid turbulence through the reactor components. Various embodiments of wire standoffs and their placement for improving reactor performance are discussed herein.

Disclosure of Invention

A reactor includes an outer tube that houses one or more reactor components and a wire standoff. The one or more reactor components may have a circular diameter and have an outer circumferential surface such that an outer diameter surface of the one or more reactor components does not directly contact the outer tube. The wire standoff may include a portion thereof that is located between the inner wall surface of the outer tube and the outer diameter surface of the one or more reactor components. As arranged, the wire standoff prevents the one or more reactor components from touching the inner wall surface of the outer tube, but the wire itself may be in direct contact with the tube wall and the one or more reactor components. The wire standoff may be secured to one or more reactor components or one or more washers also located in the outer tube.

A wire standoff for use in a reactor. The wire standoff may be a wire. The wire may have a portion located between the outer tube and a reactor component of the reactor, wherein the reactor component is located in the outer tube. When arranged in the reactor, the wire part itself, which prevents the outer tube from contacting the reactor component, may be in direct contact with the outer tube and the reactor component. The wire may have a first end and a second end defining a terminal end thereof. The first end of the wire may be fixed to a reactor component or a washer housed in the reactor. Similarly, the second end may be secured to a reactor component or a gasket of the reactor. To secure either end of the wire to the washer, the wire may have a hook. The wire may comprise an end portion having a flat section for securing the wire to a reactor component (such as a fan-shaped structure), wherein the end portion extends inwardly into the reactor component and past its outer circumferential surface.

Drawings

The following drawings illustrate various aspects of one or more embodiments of the invention, but are not intended to limit the invention to the embodiments shown.

FIG. 1 shows a cross-sectional view of a reactor tube having a plurality of wire standoffs disposed along an outer diameter face of a reactor component and disposed between an outer tube and the component.

FIG. 2 shows a perspective view of a stacked reactor component having a plurality of wire standoffs arranged along an outer diameter face of the reactor component, wherein the wire standoffs span across the surfaces of the plurality of components.

Fig. 3 shows a sectional view of a wire mount arranged on a washer for fixing the wire mount on the washer.

Fig. 4 shows a sectional view of a wire mount arranged on a washer for fixing the wire mount on the washer.

Fig. 5 shows a perspective view of a stacked reactor component having a plurality of wire standoffs arranged along an outer diameter face of the reactor component.

Fig. 6 shows a sectional view of a wire mount arranged on a washer for fixing the wire mount on the washer.

Fig. 7 shows a cross-sectional view of a wire standoff disposed through an opening in a washer for securing the wire standoff to the washer.

Fig. 8 shows a perspective view of a stacked reactor component having a plurality of wire standoffs arranged along an outer diameter face of the reactor component.

Fig. 9 shows a perspective view of a wire standoff having a hook end for securing the wire standoff to a reactor component or washer.

FIG. 10 shows a perspective view of a stacked reactor component having a plurality of wire standoffs arranged along an outer diameter face of the reactor component.

Fig. 11 shows a perspective view of a wire standoff having a zigzag pattern with ends having straight sections for securing the wire standoff to a reactor component.

FIG. 12 shows a perspective view of a stacked reactor component having a plurality of wire standoffs arranged along an outer diameter face of the reactor component.

FIG. 13 shows a perspective view of a wire standoff having a flat end for securing the wire standoff to one or more reactor components.

Detailed Description

As used herein, when a range such as 5-25 is given, this means at least or greater than 5, and individually and independently, less than or not greater than 25. The materials of construction of all or portions of the reactor components, such as the catalyst support, the fan-shaped structure, the monolithic column, the coil, the gasket, and the inner and outer tubes, as discussed herein, may comprise any suitable material known in the art, for example, metals, non-ferrous metals, metal foils, steel, stainless steel, alloys, foils, non-metals such as plastic or glass, ceramics, or combinations thereof.

The reactors described herein, sometimes referred to as stackable structural reactors ("SSRs"), may include a plurality of catalyst support members arranged around or stacked on a central support, such as a central rod, mandrel, tube, or post, etc., so as to form a monolithic column of generally circular cross-section (when viewed in the direction of fluid flow through the reactor). The monolithic column or stacked catalyst support may occupy all or part of the annular space between two concentrically arranged tubes, such as a reactor or an outer tube and an inner tube. Alternatively, the reactor component may fill the reactor tubes with or without a central support so that a central hollow section is not formed between the concentric tubes. As described herein, various modifications and embodiments of the reactor and related reactor components may be used in conjunction with the wire standoffs to improve heat transfer and reactor efficiency.

An outer tube 3, such as a reformer tube, having an inner wall surface and an outer wall surface, may house one or more reactor components 2, such as vertically stacked fan structures 2, arranged on a center rod 1. The diameter of the outer tube 3 is preferably constant along its entire length. The reactor component 2 (such as a fan-shaped structure) may be configured with a central opening or indentation 12 for receiving the central rod 1 so that the component can slide over the central rod and can be located in the outer tube. For example, a cylindrical rod 1 may be used to support a reactor component 2 having a central circular opening 12 as shown. The diameter of the cylindrical rod 1 may be the same as or slightly smaller than the diameter of the opening 12 in the reactor part. The central rod 1 may have a length corresponding to that of the outer tube 3.

The centre rod 1 may further comprise brackets, sleeves and a base plate etc. for providing a stop fitting so that the components do not slide off the centre rod. The base plate may be positioned at or near the lower end of the center rod and may have a shape and diameter or dimensions that allow for easy installation in the outer tube. For example, the stopper plate may have a circular shape having a diameter equal to or smaller than the inner diameter of the outer tube. The center rod may be preloaded with any number of reactor components or washers prior to being inserted into the outer tube.

As shown, the fan structures 2 may be stacked vertically one above the other to form a multi-layer reactor component 2. Although vertically stacked reactor components are shown here, the components may be arranged in alternative ways (such as horizontally) to accommodate orientation of the reactor or certain specifications. As described below, the gasket 4 may be inserted between one or more reactor components 2 (e.g., fan structures) as desired, e.g., each fan structure may be separated by a gasket, wherein the gasket forms an open space between the components. The ring-shaped washers 4 may be used as spacers and the reactor parts and washers may be arranged in an alternating sequence. The stacked reactor components may be arranged vertically, e.g., in the range of 0.5 to 4 feet, as desired to create a subassembly. Multiple subassemblies may be stacked together in the reactor, for example, 1 to 60 subassemblies may be stacked. The stacked subassemblies may have a height in the range of 2 to 60 feet.

A fluid to be reacted 10 such as a gas or a liquid flows substantially vertically (upward flow 10a or downward flow 10b as required) through the outer tube 3 and flows through each of the members 2 arranged on the center rod 1. The reactor component 2 directs the fluid flow in other non-vertical directions to increase heat transfer, for example, a fan-shaped structure directs or directs the fluid flow radially (perpendicular to the overall vertical direction) toward the outer tube wall. The scalloped structure may contact or be close to the inner wall surface of the outer tube 3, which effectively transfers heat from outside the reactor to the reactor component 2 and the fluid 10 contained therein. Preferably, the diameter of the fan-shaped structure located inside the outer tube is smaller than the inner diameter of the reactor tube to create a gap or free space 7 between the outer circumferential surface of the fan-shaped structure and the inner wall surface of the outer tube. The gap 7 between the outer peripheral surface of the fan-shaped structure and the inner wall surface of the outer tube may be at least 0.5, 1, 2, 3, 5, 10 or 15mm, and is preferably in the range of 0.5 to 6, more preferably 1 to 3 mm. The gap 7 facilitates heat transfer and forces the fluid flow to travel towards the inner wall surface of the reactor wall to be directed back into the reactor interior.

The stacked arrangement of the reactor components 2 is designed to promote heat transfer for performing the catalyst reaction so that the reactor components 2 and the gaskets 4 can be coated with catalyst to effectively distribute the catalyst into contact with the majority of the fluid 10 flowing through the reactor. Catalytic materials for coating reactor components are known in the art and may include, but are not limited to, nickel, palladium, platinum, zirconium, rhodium, ruthenium, iridium, cobalt, and oxides of aluminum, cerium, and zirconium.

As described below, the wire standoff 5 may have various designs and configurations and may be positioned and arranged in a number of ways with respect to the reactor component 2 and the gasket 4. Referring to the drawings, fig. 1 shows a reactor having a wire standoff 5, the wire standoff 5 being disposed within an outer tube 3 for preventing reactor components and gaskets from contacting an inner wall surface of the outer tube. As shown, the reactor components 2 are arranged vertically in a stacked manner with alternating washers within the outer tube 3. The reactor components are arranged on a central rod 1 which traverses the length of the outer tube. To prevent the stacked reactor parts and gaskets from sliding down off the central rod, a stop plate 6 is positioned at or near the lower end of the central rod 1. Fluid 10 may flow through the reactor part 2 and down/up through the outer tube 1. Fluid 10 contacts the catalyst support to effect the reaction in the outer tube.

Is fixed to the washer 4 or reactor component 2 and the wire standoff 5 is placed around the outer diameter surface of the component 2 or washer 4. The wire mount 5 may be made of any suitable material, such as metal, steel, stainless steel, alloys such as nickel and/or chromium, foils, and non-metallic materials such as plastic. For example, the wire support may be a wire, cable, cord, or filament. Preferably, the wire mount 5 is flexible so that suitable structural modifications can be made to adapt the wire mount to a particular reactor component. The wire seat 5 may preferably be made of a flexible wire having a circular diameter with a constant diameter along the entire length of the wire. The wire standoff may have a circular diameter of at least 0.25, 0.5, 0.75, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, or 10mm, preferably in the range of 0.25 to 5mm, more preferably 0.5 to 2 mm. Alternatively, a square or other cross-sectional shape may be used to make the wire standoff, as desired.

The wire standoff 5 may be designed to extend lengthwise (such as vertically) along the outer diameter surface 2a of the one or more reactor components 2 as shown. In some examples, the wire standoff 5 may span vertically across at least one reactor component, or in other cases, across substantially the entire reactor sleeve of the stacked component. The wire standoff 5 prevents the one or more reactor components and any washers 4 in the stack from directly contacting the outer tube 3 by spanning the outer diameter surface 2a of the one or more reactor components 2. As shown in the cross-sectional view, a plurality of wire seats 5 may be arranged to ensure a substantially constant annular gap 7 between the outer diameter faces of the reactor components and the washers and the inner wall surface of the outer tube. Any number of wire standoffs may be used to ensure the annular gap, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 wire standoffs may be used. The gap 7 created by the wire standoff between the reactor component and the outer diameter face of the washer and the inner wall surface of the outer tube 3 may be at least 0.25, 0.5, 1, 2, 3, 4, 5 or 10mm, preferably in the range of 0.5 to 6, more preferably 1 to 3 mm.

The wire standoff 5 may have an inward facing end 5a at each end (first and second) such that the inward facing end is bent or extended to the reactor component 2 or around the gasket 4 as shown, which may prevent the end 5a of the wire standoff 5 from jamming the reactor tube 3 during installation or operation. The wire standoff has two ends, a first end or end and a second end or end. Fig. 1 shows the end 5a of the wire standoff with a hook for securing the end 5a to the washer 4. The hook of the end 5a of the wire standoff may have a bend angle in the range of 70 to 180 degrees. As shown, the ends of the wire standoff may extend inwardly through the outer diameter surface plane 2a of the reactor component 2 (such as a fan-shaped structure), extend over the upper surface of the washer 4, and bend downwardly about a 90 degree angle around the inner diameter surface 4a of the washer 4 to secure the wire standoff 5. In this arrangement, the end 5a of the wire standoff has a 90 degree hook for securing the wire standoff to the washer.

Separately from the end portion 5a, the wire seat 5 has another portion, such as an intermediate section or portion, located between the outer diameter face 2a of the reactor component and the inner wall surface of the outer tube 3. The wire standoffs 5 may be spaced radially around the diameter of the washer 4 as desired and along other washers located above and/or below as shown to provide peripheral coverage for the reactor components.

Fig. 2 shows two wire seats 5 placed diagonally across the outer diameter surface of the stacked reactor part 2. Each reactor component has an opening 12 for receiving a central rod for placing the components in a stacked arrangement in the outer tube. An annular gasket 4 having an outer diameter 4b, a flat body section and an inner diameter 4a is positioned between each reactor component 2. The first and second ends 5a of the two wire mounts 5 are fixed to the uppermost washer and the lowermost washer. The first and second ends of the wire standoff extend inwardly toward the center of the reactor component and across the top of the flat body section of each gasket 4. As can be seen at the lowermost washer, the end 5a of the wire standoff is bent near the inner diameter 4a of the washer, such that the end is bent downward to hook the inner diameter 4a of the washer. As shown above, the wire mount 5 may have a hook portion for fixing the wire to the washer, wherein the hook portion may have a curvature in the range of 70 to 180 degrees.

When arranged in the outer tube, the fan-shaped structure 2 has a plurality of

radial fluid ducts

2b, 2c for guiding the fluid flow 10 through the reactor. As shown, the radial fluid ducts are approximately triangular in shape and extend outwardly from the central opening 12 to form an annular cross-section (when viewed from the top of the fan-shaped structure 2). The radial fluid conduits terminate along the outer diameter face of each fan-shaped structure to form triangular openings facing the inner wall surface of the outer tube. When viewed in the downward direction of fluid flow, fluid flows in one end 10a of the stacked fan structure 2, radially through the open upwardly facing triangular ducts 2b towards the outer diameter face of the fan structure 2 to contact the reactor tubes, around the outer diameter face of the fan structure 2 into the open downwardly facing triangular ducts 2c, radially towards the centre of the fan structure 2 and in the same manner onto the next fan structure and/or core until the fluid leaves the stack of fan structures at the other end 10 b. In one arrangement, for example, as shown in fig. 2, the fan structures 2 may be stacked in an arrangement in which the approximately triangular duct 2b of one fan structure, which opening faces upward, is vertically aligned with the approximately triangular duct 2c of the fan structure 2, which opening faces downward, which is located immediately above or below.

Between the two ends 5a of each wire seat 5 is a portion positioned between the outer tube and the outer surface of the reactor component 2 to prevent the component from contacting the outer tube (not shown). The intermediate portion for ensuring the gap between the outer tube and the reactor component may traverse diagonally along the outer diameter face of the fan-shaped structure as shown, or in another direction or pattern as desired, for example, a vertical direction or a curved pattern (such as a "C" shape, a spiral shape, a corrugated shape, or a zigzag pattern). The intermediate section of the wire standoff 5 may be placed diagonally at an angle in the range of 5 to 70 degrees. A plurality of wire standoffs may be arranged around the outer diameter surface of the stacked sector 2 to provide 360 degree coverage of the stacked components to ensure that a certain gap is maintained between the components and the inner wall of the outer tube. Although three components are shown, the stack may include more components, and the wire standoff may have a length to accommodate any number of components.

The end portions 5a and the intermediate portion of the wire mount 5 may be fixed to the washer 4 or the reactor component 2 in several different ways. The wire standoffs described herein may have one or more securing features. For example, each end 5a of the wire standoff may have a different securing feature, such as a hook, and the middle portion of the standoff may further include another embodiment of the securing feature. The range and variety of securing features of the wire mount may be selected as desired. The securing features of the wire standoff are preferably integrally formed with the standoff structure. For example, the wire may be bent or manipulated to form a hook or notch at either end or an intermediate portion for securing the wire standoff to the washer or reactor component.

Fig. 3 shows one embodiment for fixing the end 5a of the wire standoff 5 to the washer 4. As shown, the cross-sectional view of the washer 4 is such that the end 5a of the wire standoff 5 extends across its width on top of the body section of the washer. At the inner diameter 4a of the washer 4, the end 5a of the wire seat has a bend of about 90 degrees, so that the bent end forms a hook that fits on the inner diameter 4a of the washer. The hook prevents the wire standoff 5 from sliding or being pulled off the washer 4 during installation or operation of the reactor. The hook can be secured to the washer by a pulling force. For example, the wire standoff may be flexed or pushed over the washer to force the hook around the inner diameter 4a of the washer 4. The end 5a of the wire seat 5 may be welded, for example tack welded or laser welded, on the washer 4 to permanently weld the wire seat to the washer.

Fig. 4 shows another embodiment of fixing the wire support 5 to the washer 4. The end 5a of the wire support 5 may have a hook portion forming an approximately 180 degree bend for hooking the end around the inner diameter 4a of the washer. As shown, the inner diameter of the washer is in direct contact with the inner surface of the hook at the end. The hook may have a bend angle of less than 180 degrees, for example, at least 120, 130, 140, 150, 160, or 170 degrees.

The wire holder 5 can be secured to the washer 4 located in the outer tube by inserting the end 5a of the wire holder into an opening or indentation 14 located in the washer 4 (e.g., in the body section). The washer 4 may have one or more openings 14 for receiving the end portions 5a of the wire holder. For example, the washer 4 may have 1, 2, 3, 4, 5, 6 or more openings 14 for securing a wire standoff. The openings can be spaced along the body section of the gasket as desired and can be selected to accommodate the wire standoffs to cover the entire surface of the stacked reactor components. The opening 14 may be of any shape and have a dimension greater than the diameter or cross-sectional area of the end of the wire standoff. For example, the gasket opening 14 may be circular and have a circular diameter of at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, or 25 mm.

Fig. 5 shows a wire standoff 5 placed diagonally across the outer diameter face of two vertically stacked fan structures 2, wherein the wire standoff has two ends 5a, a first and a second end, extending through openings 14 in the gasket 4. The end portion 5a may be formed into a hook by having a bent portion in the range of 70 to 180 degrees. The hook can be forced through the opening 14 in the washer to secure the wire standoff. Fig. 7 shows the end 5a of the wire support 5 extending down through the opening 14 in the washer 4. The ends have hooks with a bend angle of about 90 degrees.

In another embodiment of securing the wire standoff to the gasket, fig. 5 shows the wire standoff with a hook or notch 5b (forming an open slot) in the middle portion. The hook or recess 5b may be a recessed portion along the length of the wire support 5, for example, in the portion located between the outer tube and the reactor component. The one or more notches 5b may be located anywhere along the length of the wire support to align with the desired reactor component 2. For example, the washer 4 may be positioned or inserted into an open slot of the hook 5b for securing the wire standoff to the washer. The wire holder can be flexed or forced around the inner diameter 4a of the washer 4 to slide the open slot of the intermediate portion over the washer to secure the wire holder. The remaining two ends 5a of the wire standoff may include a securing feature discussed herein, such as a hook with a bend angle in the range of 70 to 180 degrees. Fig. 6 shows a cross-section of the washer 4 in the open slot of the middle part of the wire holder with the notch 5 b. As shown, the inner diameter face 4a of the washer is in direct contact with the open slot formed by the notch 5b in the wire seat. It is desirable to have one or more open slot hooks 5b between the two ends 5a of the wire standoff to secure the standoff to the vertical structure of the washer 4. The plurality of open slots may provide structural integrity and rigidity to the portion of the wire standoff located between the outer tube and the outer diameter face of the reactor component.

Fig. 8 shows another embodiment of the wire standoff 5. The wire standoff may be designed to have a V-shaped middle portion. The angle of the V-shape may be in the range of 30 to 90 degrees. The V-shape of the middle portion may be arranged upwardly as shown, or downwardly so as to span the outer diameter face of one or more stacked reactor components. Alternatively, a plurality of V-shaped wire standoffs may be arranged in an alternating upward/downward pattern around the outer diameter face of the reactor component to provide 360 degrees of coverage for the outer diameter face of the component to ensure that the reactor component does not contact the outer tube. Any number of wire standoffs may be used to surround the outer diameter face of one or more reactor components. The V-shaped portion may cover at least 1, 2, 3, 4 or more reactor parts, such as a fan-shaped structure.

As shown in fig. 9, both end portions 5a of the V-shaped wire mount 5 may have hooks for fixing the mount to the washer. The hook may have a bending angle in the range of 70 to 180 degrees. The hooks may form a recess for embedding the washer, or alternatively, the end portions may have hooks that extend through openings in the washer.

In another embodiment, the wire standoff may be secured to the reactor component. The end 5a of the wire standoff may be a straight section without hooks. The flat end may extend inwardly into the at least one reactor part 2 through the outer circumferential surface, e.g. to the fluid channel or

conduit

2b, 2 c. For example, as shown in fig. 10, the straight section or section of the end portion 5a may extend into the

flow channels

2b, 2c of the fan reactor section 2. The ends may be fixed to the reactor component by welding or by a pulling force generated by flexing the wire seat 5 to fit the ends in the

flow channels

2b, 2 c. The opposite end of the wire standoff may be similarly secured to the reactor component, or alternatively, it may be secured to the washer as described above.

Fig. 10 shows that the intermediate portion of the wire support, between the two ends 5a fixed to the reactor component, may have a series of zigzag structures in an alternating "Z" pattern. A plurality of wire standoffs having a meandering pattern may be used to surround the outer diameter face of one or more reactor components 2. When disposed on the outer diameter face of the reactor component, the wire standoff may have a height of at least 3, 4, 5, 6, 7, 8, 9, 10 or more reactor components or a height of 4 to 30 inches.

Figure 11 shows a wire standoff for placement between an outer tube and one or more reactor components with a zigzag pattern of intermediate portions. Each end 5a of the wire standoff 5 has a straight section or foot for extending inwardly toward the center of the reactor. The flat sections of the end portions should be long enough to prevent the wire support from coming off the reactor component during installation. The straight portion of the end of the wire standoff may be in the range of 20 to 80 mm.

The wire standoff 5 may be placed on the outer diameter face of the reactor component 2 by bending or bending the standoff to align the two ends with the flow channels in the one or more fan structures. Once in place, the wire mount may be released to provide a non-flexed state, thereby creating tension at both ends. The end 5a may press and provide a pull fit at the flow channel to secure the wire mount to one or more reactor components. As indicated above, the ends 5a of the wire standoff may be welded to the

flow channels

2b, 2c of the reactor component 2 in order to secure them.

Fig. 12 and 13 show another embodiment of a wire mount 5 that can be fixed to the reactor component 2. Each end 5a of the wire standoff may have a straight section that may extend into the reactor component 2. The straight section may extend into the reactor component in a direction substantially perpendicular to the outer circumferential surface of the reactor component and the inner circumferential surface of the outer tube. Between the two ends 5a of each wire seat is a portion located between the outer tube and the outer surface of the reactor component to prevent the component from coming into contact with the outer tube. As shown, the intermediate portion of the wire standoff used to ensure clearance between the outer tube and the reactor component may be substantially flat and diagonally across the surface of the component.

The intermediate section of the wire standoff may be placed diagonally at an angle in the range of 5 to 70 degrees. A plurality of wire standoffs may be arranged around the outer diameter surface of the stacked fan structure to provide 360 degree coverage of the stacked components to ensure that a specified gap is maintained around the components and between the inner walls of the outer tube. Although three components are shown, the stack may include more components, and the wire standoff may have a length to accommodate any number of components.

While various embodiments in accordance with the present invention have been shown and described, it is to be understood that the invention is not so limited and that many changes and modifications may be readily made as will be known to those skilled in the art. Accordingly, the invention is not to be limited to the details shown and described herein, and includes all such changes and modifications as are encompassed by the scope of the appended claims.

Claims

1. A stackable structural reactor comprising:

a) an outer tube;

b) a plurality of fan-shaped catalyst support members arranged in a vertical stack on a center support, the plurality of catalyst support members having an outer circumferential surface, the plurality of catalyst support members being located in an outer tube;

c) a wire supporter having a portion thereof located between the outer tube and the plurality of catalyst support members, the wire supporter separating the plurality of catalyst support members from the outer tube for preventing the plurality of catalyst support members from contacting the outer tube,

wherein the outer tube houses the plurality of catalyst support members and the wire holder, each catalyst support member having a plurality of radial fluid conduits for conducting a fluid flow through the reactor, each radial fluid conduit extending outwardly from a central opening of the catalyst support member and terminating along an outer circumferential surface of the catalyst support member to form an opening facing an inner wall surface of the outer tube, the fluid flowing in one end of the stacked plurality of fan-shaped structured catalyst support members radially through the radial fluid conduit with the opening facing upwardly toward the outer circumferential surface of the catalyst support member so as to contact the outer tube, flowing around the outer circumferential surface of the catalyst support member into the radial fluid conduit with the opening facing downwardly, radially toward the center of the catalyst support member and in the same manner onto a next catalyst support member, until the fluid exits the stacked plurality of fan-shaped catalyst support members at the other end, whereupon the fluid to be reacted flows generally vertically through the outer tube and through the radial fluid conduits of each catalyst support member, the catalyst support members directing the fluid flow radially to direct the reaction fluid to the gaps between the plurality of catalyst support members and the outer tube.

2. The stackable structural reactor of claim 1, the wire standoff having a diameter in a range of 0.25mm to 10 mm.

3. The stackable structural reactor of claim 1 or 2, wherein the outer peripheral surfaces of the plurality of catalyst support members are spaced apart from the outer tube by at least 0.25mm to 10 mm.

4. The stackable structural reactor of claim 1 or 2, the wire standoff being secured to at least one of the plurality of catalyst support components.

5. The stackable structural reactor of claim 1 or 2, the wire standoff comprising an end having a flat section that extends inwardly into at least one catalyst support component through an outer periphery of the at least one catalyst support component.

6. The stackable structural reactor of claim 1 or 2, wherein a portion of the wire standoff between the outer tube and the outer peripheral surface of the plurality of catalyst support components is in direct contact with the outer tube and the plurality of catalyst support components.

7. The stackable structural reactor of claim 1 or 2, further comprising a washer in the outer tube, the wire standoff being secured to the washer.

8. The stackable structural reactor of claim 7, the wire standoff having an end secured to a washer.

9. The stackable structural reactor of claim 8, the end of the wire standoff having a hook for securing the end to the gasket, the hook of the end of the wire standoff having a bend angle in a range of 70 degrees to 180 degrees.

10. The stackable structural reactor of claim 7, the gasket having an opening for securing a wire standoff, the wire standoff having an end that extends through the opening in the gasket to secure the wire standoff to the gasket.

11. The stackable structural reactor of claim 7, the wire standoff having a hook forming an open slot, a washer positioned in the open slot of the hook to secure the wire standoff to the washer.