GB2470764A - Oscillating flow reactor - Google Patents

Oscillating flow reactor Download PDF

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GB2470764A
GB2470764A GB0909620A GB0909620A GB2470764A GB 2470764 A GB2470764 A GB 2470764A GB 0909620 A GB0909620 A GB 0909620A GB 0909620 A GB0909620 A GB 0909620A GB 2470764 A GB2470764 A GB 2470764A
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fluid
storage area
flow
permeable barrier
upstream
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David Dorab Jamshed Antia
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DCA CONSULTANTS Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/04Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds
    • B01J8/0446Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds the flow within the beds being predominantly vertical
    • B01J8/0449Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds the flow within the beds being predominantly vertical in two or more cylindrical beds
    • B01J8/0453Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds the flow within the beds being predominantly vertical in two or more cylindrical beds the beds being superimposed one above the other
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D69/00Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/14Dynamic membranes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/18Stationary reactors having moving elements inside
    • B01J19/1893Membrane reactors
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/0242Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid flow within the bed being predominantly vertical
    • B01J8/025Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid flow within the bed being predominantly vertical in a cylindrical shaped bed
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/0278Feeding reactive fluids
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/04Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds
    • B01J8/0492Feeding reactive fluids
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/16Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with particles being subjected to vibrations or pulsations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/18Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
    • B01J8/24Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique
    • B01J8/40Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with fluidised bed subjected to vibrations or pulsations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/18Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
    • B01J8/24Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique
    • B01J8/42Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles according to "fluidised-bed" technique with fluidised bed subjected to electric current or to radiations this sub-group includes the fluidised bed subjected to electric or magnetic fields
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/00008Controlling the process
    • B01J2208/00548Flow
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00Technologies for the production of fuel of non-fossil origin
    • Y02E50/30Fuel from waste, e.g. synthetic alcohol or diesel

Abstract

An oscillating flow reactor is disclosed, which can be used for one or more of catalytic processes, non-catalytic processes, filtration processes, fluid adsorption processes, fluid separation processes, concentrating kinetic energy and concentrating potential energy. The reactor can take a constant feed, variable feed, irregular feed, intermittent feed, or episodic feed. Fluid discharge can be constant, variable or intermittent. The reactor requires at least one fluid reactant (or feed), but can also process solid reactants. The reactor operates by cyclically changing the energy distribution within the fluids between kinetic energy and potential energy, with different ratios of energy transfer between kinetic and potential energy being present in different parts of the reactor. The key component of the reactor is an elastic permeable barrier, such as a membrane or fluidised bed.

Description

Oscillating Flow Reactor
DOCUMENTS CITED
European Patent Documents GB 0817567.1 25th September, 2008. Capture of carbon oxides. Antia, D.D.J.
Other Documents Coulson, J.M., Richardson, J.F., 1988. Chemical Engineering, vol.1 to 6. Pergamon. ISBN: 0-08-0229 1-0 Mulder, M., 1996. Basic Principles of Membrane Technology. Kluwer Academic Publishers.
Dordrecht. ISBN: 0-7923-4247-X Kotz, J.C., Treichel, P., 1996. Chemistry and Chemical Reactivity. Saunders College Publishing.
ISBN: 0-03-001291-0 Cartmell, M., 1990. Introduction to linear, parametric and nonlinear vibrations. Chapman Hall. ISBN: 0 412 30730 8 Brown, T.L., LeMay, H.E., Bursten, B.E., 2001. Chemistry. The central science. Prentice Hall, ISBN 0-13-0 103 10-1 ASCE, 2001. Selected Geotechnical papers of James K. Mitchell. American Society of Civil Engineers, Geotechnical Special Publication. ISBN-13: 9780784405673 Douglas, J.F., Gasiorek, J.M., Swaffield, J.A., 2001. Fluid Mechanics. Prentice Hall. ISBN 0 582 Tongue, B. H., 2002. Principles of vibration. Oxford University Press. ISBN: 0-19-514246-2 Brodkey, R.S., Herschey, H,C., 2003. Transport phenomena: v. 1: A unfIed approach. Brodkey Publishing. ISBN-13: 978-0972663595 Brutsaert, W., 2005. Hydrology an introduction. University Press, Cambridge. ISBN-13: 978-0-52 1-82479-8 Metz, B., Davidson, 0., Coninck, H., de, Loos, M., Meyer, L., 2005. Carbon dioxide capture and storage. 443 pp., IPCC (Cambridge University Press). ISBN-13: 978-0-521-86643-9.
Antia, D.D.J., 2008a. Oil polymerisation and fluid expulsion from low temperature, low maturity, overpressured sediments. Journal of Petroleum Geology, 31, 263 -282 Antia, D.D.J. 2008b Prediction of overland flow and seepage zones associated with the interaction of multiple Infiltration Devices (Cascading Infiltration Devices). Hydrological Processes, 21, 2595 -26 14.
Green, D.W., Perry, R.H., 2008. Perry's chemical engineers handbook. McGraw Hill, New York.
ISBN: 978-0-07-142294-9 Lide, D.R., 2008, CRC Handbook of Chemistry and Physics, 89th Edition., CRC Press. ISBN-13: 978- 1-4200-6679-1
FIELD OF INVENTION
The invention is an oscillating flow reactor, which can be used to undertake catalytic, or non catalytic reactions. It can also be used to filter fluids and separate fluids.
BACKGROUND TO THE INVENTION
Catalytic reactors (including but not limited to fixed bed, packed bed, coated wall, fluidised bed, membrane, nano-channel, nano-tube, microchannel reactors) are operated under constant conditions.
The pressures and flow rates located immediately upstream and immediately downstream of the catalyst bed are maintained at constant values (e.g. Coulson and Richardson, 1988; Mulder, 1996; Green and Perry, 2008). The driving force remains constant (e.g. Coulson and Richardson, 1988; Mulder, 1996; Green and Perry, 2008). These operating conditions create a stable chemical, pressure and temperature environment within the reactor.
Equilibrium chemical reactions comprise forward and backward reactions. The desired outcome is to maximise the ratio of forward to backward reactions. This is achieved by maximising the contact time within the desired environment and minimising the time spent outside the desired environment. The product yield, CB, associated with catalytic processes is a function of space velocity, SV (SV reactant deliver' velocity (or unit volume, or unit mass) per unit time per unit volume (or unit mass) of catalyst (e.g. m (reactant) hrt m3 (catalyst)). In a constant flow environment, C8 will decrease, as SV increases.
It was unexpectedly discovered that if the reactant spent part of the time travelling through the catalyst bed at high velocity and part of the time travelling through the catalyst bed at a lower velocity (as a result of a travelling pressure (driving force) wave passing through the catalyst bed), that (i) the catalyst bed had a high sweep efficiency, (ii) the product fluid could have an increased, C8, associated with a specific SV, (iii) the CB and product selectivity could be altered by altering the amplitude, periodicity and shape of the driving force wave.
It was also unexpectedly discovered that part of the potential energy, or the kinetic energy, could in certain circumstances be converted to an induced ionisation energy. This discovery can allow C8, to increase with increasing SV. This discovery is contrary to the prior art and is demonstrated in Example 8 using an ionic substance as a catalyst and a covalent fluid as a reactant. This discovery requires the presence of one or more ionic substances, where the ionic substance can be a reactant, or a catalyst, or a combination thereof, The invention incorporates these discoveries and provides an alternative, versatile, reactor type.
A side effect of the process is that potential energy and kinetic energy are concentrated during different stages of the driving force wave. This allows dispersed energy to be concentrated for use in separation processes as potential energy, and kinetic energy to be concentrated for recovery as motive (or electrical) power.
The defining difference between this reactor type and existing reactors are its structure and mode of operation. The defining characteristics of the invention are (i) the presence of an elastic permeable barrier (EPB). The EPB can optionally contain, or be constructed from, catalyst. The EPB separates an upstream storage area from a downstream storage area. This structure bears some superficial similarities to an existing reactor where a catalyst bed separates a downstream conduit (or volume) from an upstream conduit (or volume). However, the invention can be constructed without catalyst in the EPB, and can be structured by placing the catalyst in an upstream storage area, or a downstream storage area, or a combination thereof. The catalyst can be a solid, or a fluid, or a combination thereof.
(ii) the average pressure in the upstream storage area is greater than the average pressure in the downstream storage area.
(iii) All continuous flow reactors (fixed bed and fluidised bed) have a constant driving force between an upstream area and a downstream area. This is achieved by maintaining a constant pressure in the upstream area and the downstream area. In this invention, the pressures in the upstream storage area cycle between lower and higher pressures; and the pressures in the downstream storage area cycle between higher and lower pressures. This creates a variable driving force across the EPB. At any instant in time, the pressure in the upstream storage area is greater than, or equal to, the pressure in the downstream storage area. The relationship between the pressure in the upstream storage area and the pressure in the downstream storage area is in a continual state of flux. This continual pressure variation represents a major difference between this invention and the prior art.
(iv) In this invention, kinetic energy received in the upstream storage area is temporarily converted to potential energy (and some of this energy may in certain circumstances be converted to ionisation energy). The amount of kinetic energy converted to potential energy cyclically varies with time. In an existing reactor, the proportion of kinetic energy converted to potential energy remains constant and does not cyclically change with time.
(v) In this invention, potential energy stored in the upstream storage area is cyclically converted to kinetic energy (and some of this energy may in certain circumstances be converted to ionisation energy). In an existing reactor, the proportion of potential energy converted to kinetic energy remains constant and does not cyclically change with time.
(vi) In this invention, the flow rate through the EPB (and catalyst bed, or catalyst beds) cyclically varies with time. The maximum flow rate through the EPB in a flow cycle is greater than the average flow rate into the upstream storage area. The minimum flow rate through the EPB in a flow cycle can be zero. Existing reactors require a constant flow rate through the catalyst bed.
(vii) This invention is highly flexible and can accommodate a feed which is delivered at a constant rate, or a variable rate, or an irregular rate, or intermittently, or episodically.
Existing reactors require a constant feed.
(viii) This invention can accommodate a demand for product from the reactor, which is continuous, or is intermittent, or is variable. Existing reactors produce a continuous stream of product.
(ix) This invention can be structured to operate at a lower internal pressure for a specific feed flow rate than a fixed bed reactor, or a fluidised bed reactor, for a specific length of catalyst bed and feed flow rate.
Invention Applications This invention has a number of potential commercial applications. These include, but are not limited to: (i) the processing (treatment, filtration, adsorption) of storm water runoff, process water, waste water, foul water, riparian water, reservoired water (or water from any other source) to produce water for one or more of riparian discharge, industrial purposes, chemical purposes, process purposes, manufacturing purposes, agricultural purposes, infiltration purposes, and drinking purposes, (ii) the processing of flue gases, exhaust gases, waste gases and other gases to remove CO2 and manufacture one or more of oil and organic chemicals (including but not limited to CXHYOZ, CXHYNZ, CXHYSZ, CXHYCIZ, and combinations thereof) from gases containing CQ (e.g. CO, C02) and hydrogen containing gases (e.g. H2, CXHYOZ, etc.) (iii) production of organic chemicals from synthesis gas (iv) the manufacture of synthesis gas (v) the production of products using fermentation processes (including but not limited to biogas, alcohol, acetic acid, acetate) (vi) the processing of blood (e.g. dialysis), (vii) the manufacture of biodiesel and bioftiels from vegetable oils or biomass or a combination thereof (viii) catalytic chemical processes (ix) non catalytic chemical processes.
(x) recovery of metals from waste materials and mineral ores; production of metals and metal nano-catalysts; production of metal carbonyls (xi) production of carbon nano-tubes and carbon nano-catalysts (xii) pyrolysis, carbonisation, gassification and coking processes (xiii) removal of sulphur compounds from natural gas, synthesis gas, process gas (xiv) filtration, absorption, and desorption processes (xv) fluid separation processes (xvi) increasing the effective storage capacity of a CO2 sequestration reservoir.
The present invention therefore comprises a combination of features and various other characteristics and advantages which will be readily apparent to those skilled in the art upon reading the detailed descriptions of the invention and by referring to the accompanying non-limiting drawings and non-
limiting examples.
DEFINITIONS AND MATERIALS
EPB: Elastic permeable barrier (2), Figure Ia Fixed Bed Reactors: include, but are not limited to, packed bed, membrane, coated wall, nano-tube, micro-channel, and nano-channel reactors. They include all continuous feed catalytic reactor types defined in Coulson and Richardson (1988), Mulder(1996), and Green and Perry (2008) which are not fluidised bed reactors. Fixed bed reactors require the presence of solid catalysts as either a coating, or impregnation, or particle, or a combination thereof.
Fluidised Bed Reactors: require the presence of solid catalysts as particulate matter. They include all continuous feed fluidised bed catalytic reactor types defined in Coulson and Richardson (1988) and Green and Perry (2008).
GHSV: Gas hourly space velocity, expressed in units of reactant per hour per unit of catalyst.
Units can take any form (e.g. m3 (reactant) hr1 m3 (catalyst)) OFR: Oscillating Flow Reactor Membrane Material: Mulder (1996); Green and Perry (2008) provide non limiting examples of suitable membrane construction methods, construction materials and non limiting examples of suitable membrane construction material. The membranes can be structured in any form (e.g. tubes, plates, discs, monoliths, etc.) and may be cast, or woven, or formed by another method.
Particulate Material: Particulate material includes all forms of natural and artificial solid material, which is present in particulate form. Non-limiting examples include nano-particles, powder, granules, particles, crystals, grains. Particles can assume any shape and have dimensions between 10 m and 10 m. The settling velocity, shape, density, composition, porosity, and pore structure of the individual particles can be structured to meet the appropriate reaction requirements. The particles can have a unimodal, or multimodal, size distribution. The average, standard deviation, skewness and kurtosis for one or more parameters may remain constant during operation or may vary during operation. Particles can be constructed from inert material, support material, catalyst, reactant, absorbent, desorbant, reactant, filtrate or a combination thereof. Particles can be composed of a single material, or a variety of materials. They can be constructed from organic material, or inorganic material, or a combination thereof. Suitable materials include, but are not limited to, organic matter, layered silicates, hydrated silicates, fullerines, ash, sulphides, silicates, ortho-silicates, ring-silicates, chain silicates, sheet silicates, framework silicates, suiphides, sulphates, carbonates, hydroxides, oxides, phosphates, halides, pyroclastic material, hydrated silicates, plastics, polymers, (and other synthetic organic material), sediments, rocks and minerals.
Reactor Construction: The reactor is constructed from any suitable material. Non-limiting examples of suitable material are provided in Coulson and Richardson (1988), Mulder (1996) and Green and Perry (2008). All or part of the reactor is insulated, or uninsulated, or a combination thereof. The reactor is unheated, or internally heated, or externally heated, or a combination thereof. One or more heat exchangers can be present. The external wall of the reactor is impermeable, or perm-selective, or permeable, or permeable and porous, or allows fluid diffusion through the walls, or a combination thereof. The diameter and cross sectional form of the reactor(l) between the upstream valve (6) and the downstream valve (8) may be constant, or may vary along all, or part, of its length (Figure Ia). The reactor (I) is constructed without access points, or with access points to one or more of its internal sections. The reactor can be constructed in any size.
Valve: Method, or apparatus, or a combination thereof, designed to control, or exercise control, over the flow rate in a conduit. Non-limiting examples of valves are provided in Green and Perry (2008). A valve can also include a compressor, pump, blower, exhauster, weir, sluice, and adjustable flow restrictor of any kind. A valve is constructed to be able to (I) adjust flow rates through a conduit and has the ability to terminate flow through a conduit, or (ii) adjust flow rates through a conduit, without having the ability to terminate flow through a conduit, or (iii) terminate flow through a conduit without having the ability to adjust flow rates through a conduit.
DESCRIPTION OF THE INVENTION
This invention is an oscillating flow reactor. The reactor is constructed as a permanently located structure, or a mobile structure, or a reusable structure, or a transportable structure, or a combination thereof. The reactor can be constructed as a nano-reactor or a larger sized reactor. The reactor is used to undertake one or more of catalytic reactions, fluid treatment, fluid separation, filtration, and non-catalytic reactions.
The invention (Figure la) comprises a reactor (I) containing one or more elastic permeable barriers (2), upstream storage areas (3), downstream storage areas (4), upstream valves (6), downstream valves (8), upstream conduits (5) and downstream conduits (7). The elastic permeable barrier (2)is termed EPB.
One or more Elastic Permeable Barriers (2) are located between the upstream valve (6) and the downstream valve (8). Each pair of Elastic Permeable Barriers (2) arranged in series are separated (Figure Ib) by an intermediate storage area (700). An intermediate storage area (700) is operated as a downstream storage area (4) for the upstream EPB (2) and an upstream storage area (3) for the downstream EPB (2). The invention includes a method, or process, or apparatus, or a combination thereof which is designed to create a travelling pressure wave through the EPB (2).
Figure Ia illustrates the essential elements contained in this invention. These elements are contained in a single module, or a collection of modules. The reactor (I) must contain one or more EPB (2).
The invention can optionally be constructed as a number of modular process plant units. The modules can be used independently, or combined in series, or parallel, to create a process plant.
EPB (2) Flow Rate The flow rate through the EPB (2) is controlled by three parameters (i) cross sectional area of the EPB (2), (ii) permeability (k) of the EPB (2) to the fluid component at the specific operating temperature and pressure, (iii) the difference in potential energy (driving force) between the upstream storage area (3) and the downstream storage area (4).
DEFINITIONS USED IN THE CONSTRUCTION OF A TRAVELLING WAVE THROUGH
THE EPB (2) Non-limiting Equations are provided in this specification in order to: (i) illustrate operability; (ii) to demonstrate how the invention is constructed and operated; and (iii) highlight the difference between this invention and existing reactor types. Other methods (equations) used to calculate the various parameters exist and they are specifically incorporated.
1.0 Driving Force Through the EPB (2) The difference in potential energy between the upstream storage area (3) and the downstream storage area (4) (less any pressure (potential energy) losses) is the Driving Force for the fluid flow. The driving force (AP) is approximated as:-AP=PU-PD--PL (I) Where PL pressure losses (Pa) associated with the flow across the EPB (2); P the pressure (Pa) in the area located immediately upstream of the EPB (2); P0 -the pressure (Pa) in the area located immediately downstream of the EPB (2). The pressure P is exerted by a standing (static) body of fluid (which can be pressurised), or a flowing fluid (which can be pressurised), or a combination thereof.
The pressure (Pa) exerted by a static fluid on a basal surface (e.g. a fluid-fluid contact or a membrane or a surface) is calculated (Douglas et al, 2001) as d1gh, where df = fluid density (kg m3); g = acceleration due to gravity (m s'); h = a column (m) of a given fluid of mass density d, which would be necessary to produce this pressure.
Existing reactors require that LP, P, P0, and PL through the catalyst bed remain constant and do not change with time. In this invention LP, PU, and P0 cyclically change from higher to lower values with time. PL may change with time, or may remain constant.
2.0 Fluid Flow Rate Through the EPB (2) The fluid flow rate is described (Mulder, 1996) by the equation:-QkiPorQk(iP-&) (2) Where Q flow rate (m3 m2 s'); k permeability (m3 m2 s' Pa5; P Driving Force (Pa); i\ = correction for fugacity, or another form of correction. Permeabilities may change with flow type (e.g. viscous flow, diffusion flow, turbulent flow, laminar flow) and fluid type. Flow type (and permeability) can change with P. Flow can be turbulent or laminar. iW across the EPB (2) must vary with time. The term fluid is applied to any material that continually deforms (flows) under an applied shear stress.
Fluids include both Newtonian fluids and non-Newtonian fluids. Existing reactors require that Q, k, P, and E through the catalyst bed, remain constant and do not change with time.
In this invention, the EPB (2) is used to create a continual disequilibrium within the reactor where zP, Pu, P0 and L are in a continual state of flux. This results in the fluid flow rate, Q, through the EPB (2) cyclically varying with time, even if the flow rate into the reactor through the upstream conduit (5) is constant. The flow rate through the downstream conduit (7) can remain constant, or may vary with time.
3.0 EPB (2): Driving Force Wave A iP wave can be constructed and designed, or may have a random construction, or a combination thereof. The P wave can assume any shape, amplitude and frequency, including but not limited to, symmetrical, or asymmetrical, or sinusoidal, or triangular, or harmonic, or Fourier, or square, or spiral, orscroli, or trigger, or pulse, or a wave train, or another type of wave, or a combination thereof (e.g. Cartmell, 1990; Douglas et al, 2001; Tongue, 2002). The wave can be a shock wave resulting from an abrupt change in force level, or an impulsive force, or pulsed force, or a combination thereof. The wave form can be damped, or undamped, or underdamped, or overdamped, or a combination thereof. The wave amplitude declines with time, or increase with time, or remains constant with time, or a combination thereof, The wave can be a kinematic wave, or a phase wave, or a combination thereof The wave can be a pulse wave.
Higher periodicity waves can be supplemented with shorter periodicity waves. Wave structures can be composite. A pressure management system can optionally be used to control, or define, one or more aspects of the waves. Waves can be supplemented by artificially induced waves associated with ultrasonic equipment, wave generating equipment, heating, or cooling, of fluids located in one or more of the upstream storage area (3), upstream conduit (5), downstream storage area (4), downstream conduit (7), EPB (2), and intermediate storage area (9). Wave periodicity can take any form and can have any duration. In some embodiments, the periods may have durations of a few nano-seconds. In other embodiments, the periods may have durations of hours, or days.
In this specification, the EP wave cyclically alters P and P0. The wave can be generated by alterations to k in the EPB (2), or by the use of apparatus which has the effect ofcyclically altering Pu and P0, or a combination thereof The alterations to k can be induced by changes in iW; or by chemical changes in the EPB (2); or by changes in the adsorption, or desorption, of specific fluids; or by osmotic changes within the EPB (2); or by the expansion, or contraction, of pore radii within the EPB (2); or by an increase, or decrease, in the proportion of dead end pores in the EPB (2); or by a change in the relative proportion of different types of porosity in the EPB (2), when more than one type of porosity is present; or by an alteration in the size distribution of pore throat radii within the EPB (2); or by an alteration of pore morphology; or by an alteration in fluid composition; or by a combination thereof.
4.0 Minimum Driving Force Required to Initiate Viscous Flow through the EPB (2) PM, is the minimum driving force, or pressure, required to initiate viscous liquid flow (e.g. Mulder, 1996, p.1 71). For gases the minimum driving force (PM) is defined by the Knudsen Number (KN), or another parameter associated with a specific type of diffusion (e.g. Mulder, 1996). When the driving force is less than PM, the principal flow mechanism is bulk diffusion or Knudsen Diffusion. The minimum driving force, PM, required to initiate viscous flow through the EPB (2) is defined as PM = -2 aIr (cos Oa -cos Ob) or -2 aIr (cos 0) (3) (Mulder, 1996, Eq. vt-I I0;ASCE, 2001, p. 148; Brutsaert, 2005, Eq. 8.5; Antia, 2008a, p. 264; 2008b, p.2612);a = surface tension of liquid-gas interface, Nm' (Lide, 2008, p. 6-4), a varies with temperature (Lide, 2008, p. 6-4); 0, = contact angle of the advancing meniscus; °b = contact angle of the receding meniscus; 0 = contact angle of the meniscus; r = pore throat radius, m.
This invention allows iP< PM during part of a flow cycle and allows 1W> PM during part of a flow cycle. In some embodiments of the invention, i\P will always be less than PM. In some embodiments of the invention, iW will always be greater than PM. In some embodiments, the EPB (2) may contain a fracture (or other form of) porosity, which requires a driving force of P,., to initiate flow with a permeability kF. PFJ may be greater than, or less than, PM.
4.1 The Knudsen Number (KN) The Knudsen number (KN) is defined (Brodkey and Hershey, 2003, Eq. 5.74; 5.75) as:-KN=XAX (4) = [(32TlAh\P) (RT/2itM)°5] (5) XA = mean free path length of the pore, m; 1A viscosity of gas, kg rn' s' (Lide, 2008, p.6-196); x pore diameter, m; T= Temperature, K; R gas constant, (Lide, 2008, p.1-2); M molecular weight of gas. Knudsen diffusion occurs when K,>"a" and viscous flow occurs when K<"b". A transition zone may apply when "b" Kiv "a" where gas flow is by viscous flow and Knudsen diffusion (Brodkey and Hershey, 2003, p.1 84). "a" may be approximated as 10 (Brodkey and Hershey, 2003) or another number; "b" may be approximated as 10.2 (Brodkey and Hershey, 2003) or another number. "a" and "b" may vary with gas type, pressure, temperature, the physical structure of the EPB(2) or another parameter.
5.0 Intrinsic Permeability Two types (or groups) of flow are recognised through an EPB (2). They are viscous flow and diffusion.
These flow types are described in detail in Coulson and Richardson (1988), Mulder (1996), and Green and Perry (2008).
5.1 Knudsen Diffusion The intrinsic permeability, k, associated with Knudsen diffusion can be approximated (Mulder, 1996; Eq. V-59) as:-k= [it n, r2Dk}I[RTT] (6) = number of moles of gas, when the flow rate Q is expressed in moles m2 s';when Q is expressed in m3 m2 S', n,,, is expressed in m3; I mole of gas at I atmosphere pressure and 00 C temperature occupies 22.41 litres (Brown et al., 2000, p. 363). Dk = Knudsen diffusion coefficient = 0.66 r ([8R7]/ [it M])°5 (Mulder, 1996, p.227), T pore tortuosity.
5.2 Viscous Flow The Hagen-Poisseuille equation defines k for viscous flow (Mulder, 1996, Eq. V-54; Brutsaert, 2005, Eq. 8-24; Antia, 2008a, Eq. 1) as:-k=pr2/ry (7) where p = porosity; 11 = viscosity, N s' m2; y = complexity of pore geometry.
6.0 Kinetic Energy and Potential Energy A variety of methods have been used to define both kinetic energy and potential energy (e.g. Coulson and Richardson, 1988; Douglas et al, 2001; Green and Perry, 2008). All definitions are specifically incorporated. Potential energy is energy stored within a physical system (e.g. upstream storage area (3), downstream storage area (4)) which has the potential to be converted into another form of energy.
Kinetic energy is the energy required to accelerate a fluid of a given mass from rest to its current velocity.
6.1 Total Energy From the second law of thermodynamics it follows that the total energy (ET) in the system remains constant, but can be transferred from one form to another e.g. ET=EK+Ep+ETH+E2 (8) kinetic energy, E = potential energy, ETH = heat energy, E2 = ionisation energy. From the second law of thermodynamics it follows that, provided ET remains constant: (i) EK can be transformed into one or more of E, ETH and E2 in the upstream storage area (3) (or downstream storage area (4)); and (ii) E, can be transformed into one or more of EK, ETH and E2 in the EPB (2).
6.2 lonisation Energy The velocity of an electron is the sum of its potential energy and kinetic energy. For example, the energy (E1) possessed by an electron in the nth orbit of a H atom is given by the Quantum Theory equation (Kotz and Treichel, 1996, p. 327):-E1 (J/atom) -R1h1c/n2 (9) = a proportionality constant, h1 Planc's constant, c is the velocity of light, n is a unitless integer (quantum number) having values of 1, 2, 3 and so on (but not fractional values). The ionisation energy (E2) is (Kotz and Treichel, 1996, p. 333):-E2 = -R1h1c(( 1 /I1(Final)2)(1 /n(Ifliaj)2) (10) 1l(Fjnal) = quantum number during reactor operation; (tnjtial) quantum number prior to reactor operation; n(Final) can change as the flow rate, Q, through the EPB(2) changes.
7.0 Porosity Expansion A variety of equations can be used to describe porosity ((p) expansion (for spherical and non-spherical particles) and they are specifically incorporated. The equations provided here are used to illustrate operability of the invention. Adjusting p automatically changes one or more of Q, PM, PFI, PF, PFIuid, KN, k, r, i, r, y. Existing reactors require that iSP, p, Q, PM, Ps,, PF, PFtUd, KN, k, , r, , T, and remain constant during operation. A cyclic variation in Q is achieved in this invention by (i) cyclically altering iP while keeping p, PM, P,,, P,, Pp/,,,, KN, k, , r, r, t, and y constant, or (ii) cyclically altering iP and cyclically altering one or more of (p, PM, Pt,, P, PFIUId, KN, k, , r, r, and, or (iii) keeping /P constant and cyclically altering or more of (p, PM, P,.,, P, PFluid, KN, k, , T, 11, 1, and y, or (iv) a combination thereof 7.1 Particle Bed Expansion The EPB (2) can be constructed from particles, with an excess storage volume, which allows the particle bed to expand. When eP exceeds the critical pressure, LPF, the porosity starts to expand and the grains cease being wholly grain supported. PF for spherical particles can be estimated (e.g. Leva etal, 1951) as:- 1\PF= V/A(1-4)(d-d)g (11) Where A cross sectional area of the particle bed (m2); Vt volume of the particle bed (m3); 4i gross particle bed porosity (voidage) (0<4 <1.0); d = density of the particles (kg m3). When EP is greater than P1, the permeability (k) will increase as iP increases. In this environment when LW is less than PF then p, PM, K, k, , r, , r, and y remain constant. When i\P is greater than PF then p expands, resulting in a change in one or more of PM, KN, k, , r, i, r, and * Failure to distribute P evenly across the EPB (2) can result in flow channelling where the flow rate varies within the EPB (2) as a function of the variation in W. 7.2 Flow Channelling Channelling, piping and macropore development results in an increase in the rate ofP across the EPB(2) and is considered beneficial. It results in an increase in Q, an increase in k, an increased rate of Pu decrease, an increased rate of P0 increase and may result in reduced PL during flow through the EPB (2). When i\P reduces below a critical value, the channelling flow effectively ceases and the channels/macropores/pipes collapse. This allows P to increase, iP to increase, Q to decrease, and P0 to decrease. iW2 can be less than PM. The P associated with the development of channelling may vary on each i\P cycle. The EPB (2) can include apparatus, or a method, designed to periodically homogenise, or otherwise reconstruct, the particulate EPB (2).
7.3 Particle Bed Expansion: Fluidisation Fluidisation occurs when the velocity of the flow is sufficient to allow any particle within the fluidised zone to continually shift position relative to neighbouring particles. These shifting particles are termed "stationary particulates" as the buoyant upward force of the flowing fluids matches their downward gravitational force. Particles are elutriated, when iP exceeds iWFJUId. An example (e.g. Coulson and Richardson, 1988, vol. 2. Eq. 6.3) of an equation designed to define the minimum flow rate required to fluidise a bed of spherical particles (QMFV) is:-QMFV O.00554)3/(14))(da2(ds_dj)g/1) = kn,d iPFIujd (12) d5 particle density, kg m3; df= fluid density, kg m3;d0 particle diameter, in; g acceleration due to gravity, m s2; 4) voidage; 1 viscosity, N s' m2; knjd fluidisation permeability; LWFIUId driving force required for fluidisation to occur, The pressure release and particle redistribution function of fluidisation in this invention allows the EPB (2) to have a vertical, or inclined, or horizontal orientation.
8.0 Porosity Redistribution The porosity weighting of some materials is able to change in response to changes in Eh and p1-I, or presence of chemicals, or P, or a combination thereof. The total porosity (q) is split between intra-particle porosity (q1) and the inter-particle porosity (p2), and other forms of porosity. i.e. (ps) (13) The porosity weighting can be changed with time within the EPB (2). These changes can be sudden or gradual. The changes can be cyclic and may vary with iSP. Each type of porosity has a specific value of k, which may vary with P or changes in the chemical environment. Altering the porosity weighting alters the permeability of the EPB (2).
9.0 CB It is established (in a fixed bed reactor and a fluidised bed reactor) that as SV decreases CB increases.
The exact relationship varies with chemical reaction, catalyst and operating conditions (e.g. reactant concentrations, temperature, pressure). In an oscillating flow reactor the variable flow rate through a catalyst bed located either in the EPB (2), or in the upstream storage area (3), or the downstream storage area (4) alters the expected relationship between SV and CB.
This invention has unexpectedly discovered that CB (and product selectivity) is enhanced, or altered (relative to a conventional reactor): (I) by adjusting the difference between Q at the peak of a flow cycle and Q at the base of a flow cycle; or(ii) by adjusting the ratio of the volume of fluid discharged to the downstream storage area (4) on each flow cycle relative to the volume of fluid held in the catalyst bed; or (iii) by making other adjustments to the wave form; or (iv) by a combination thereof.
10.0 Role of Storage Areas In this invention the volume of fluid present immediately upstream (upstream storage area (3)) and downstream (downstream storage area (4)) of the EPB (2) is continually changing. The principal role of the upstream storage area (3) is to store and concentrate kinetic energy as potential energy. This potential energy can be episodically released as kinetic energy during periods of high flow rate through the EPB (2). The principal role of the downstream storage area (4) is to store and concentrate kinetic energy received in fluids discharged from the EPB (2) as potential energy. This potential energy is released as kinetic energy contained in the product fluid in a controlled manner through the downstream conduit (7).
11.0 Construction of Particle Bed The EPB (2) may be constructed as a particle bed. A particle bed is constructed from any particulate material, selected from reactant, or catalyst, or inert material, or a combination thereof. The principal variables include, but are not limited to, the particle size, pore throat radii, pore shape, particle density, particle shape, particle roughness, particle composition, porosity, and permeability. One or more of these parameters can be unimodal or multimodal. The parameters can be positively, or negatively, skewed and can have a positive, or a negative, kurtosis. These parameters can be adjusted in a variety of combinations in order to construct the required relationship between permeability, and Driving Force (AP). In some embodiments one or more types of porosity will expand and contract during the oscillating flow cycle, or over time, or a combination thereof.
The changes from a grain supported to a fluid support particle bed (or vice versa), as P changes, can be designed to be abrupt or gradual, As iW decreases the flow rate decreases and flow switches from a fluid supported flow regime to a lower flow rate grain supported flow regime.
The value of PM, APF, APF/, and APFIUId is altered by changing the physical parameters associated with particles and the particle size distribution. The required relationship between flow rate and driving force is constructed by altering particle density, size, shape, modality, and particle composition.
The variations may affect one or more of the average, standard deviation, skewness, kurtosis, number of modal peaks, cumulative frequency and histogram distribution.
BRIEF DESCRIPTION OF FIGURES
The figures provide schematic representations and non-limiting examples of some embodiments of the invention.
1. Figure 1. Essential features of the invention: Figure Ia-Basic Invention; Figure Ib, Variant of the invention containing more than I EPB (2) 2. Figure 2. Standard Processing Module (600). Figure 2a -Standalone module; Figure 2b -module used in conjunction with one or more other modules. Arrows indicate directions of fluid flow.
3. Figure 3. Standard Processing Module (600) with pressure regulating vessels. Figure 3a -Standalone module; Figure 3b -module used in conjunction with one or more other modules.
4. Figure 4. Standard Processing Module (600) with dense fluid product removal. Figure 4a -Standalone module; Figure 4b -module used in conjunction with one or more other modules.
5. Figure 5. Pressure Management or fluid displacement EPB (2) Module (603) 6. Figure 6. Solid Feed or particle or particulate EPB (2) Module (601) 7. Figure 7. Membrane or Membrane EPB (2) Module (602). Arrows indicate directions of fluid flow.
8. Figure 8. Standard Processing Module (600) containing a horizontal EPB (2) containing particulate material. Arrows indicate directions of fluid flow.
9. Figure 9: Illustrative Example EPB (2): Case A -Details provided in Table I 10. Figure 10: Illustrative Example EPB (2): Case B -Details provided in Table I II. Figure 11: Illustrative Example EPB (2): Case C -Details provided in Table I 12. Figure 12: Illustrative Example EPB (2): Case D -Details provided in Table I 13. Figure 13: Illustrative Example EPB (2): Case E -Details provided in Table I 14. Figure 14: Illustrative Example EPB (2): Case F -Details provided in Table I 15. Figure 15: Illustrative Example EPB (2): Case G -Details provided in Table 1 16. Figure 16: Illustrative Example EPB (2): Case H -Details provided in Table I 17. Figure 17: Illustrative Example EPB (2): Case I -Details provided in Table I 18. Figure 18: Illustrative Example EPB (2): Case J -Details provided in Table I 19. Figure 19: Illustrative Example EPB (2): Case K -Details provided in Table I 20. Figure 20: Illustrative Example EPB (2): Case L -Details provided in Table I 21. Figure 21: Case M -Packed or Fixed Bed Operation -Details provided in Table I; OFR Oscillating flow reactor.
22. Figure 22: Case M -Comparison of iW associated with oscillating flow reactor (Figure 9) and packed bed reactor (Figure 21). -Details provided in Table I 23. Figure 23: Case N -Fluidised Bed reactor -Details provided in Table 1. OFR = Oscillating flow reactor.
24. Figure 24: Case N -Comparison ofP associated with oscillating flow reactor (Figure 9) and fluidised bed operation (Figure 24). -Details provided in Table I 25. Figure 25. Example experimental flow rate through a particulate EPB (2), fluid = water; Constant flow rate of water to the EPB (2); IPF inter-particle flow; MF macropore flow/flow in expanded porosity; FF Fluidised flow; Particle Density (measured) = 2.71 gms/cm3; average particle diameter = I mm; measured minimum pressure (PM) required to initiate inter-particle flow 40 Pa; 0.05 m high particle bed; 0.02 m diameter particle bed; 0.0005 m screen mesh used on brass screens (415), (421); EPB (2) vertical length 0.15 m.
26. Figure 26. Example experimental sequence of oscillating flow cycles through a particulate EPB (2) (Figure 25) illustrating that oscillating flow cycle durations can vary between cycles, and the distribution of flow can vary both within and between cycles; IPF inter-particle flow; MF = macropore flow/flow in expanded porosity; FF = Fluidised flow 27, Figure 27: Illustrative Example SPM(600): Case 0 -Variation in pressure (Pu and P0) with time -Details provided in Table 2 28. Figure 28: Illustrative Example SPM(600): Case 0-Variation in the volume of stored fluid in the upstream storage area (3) and downstream storage area (4) with time -Details provided in
Table 2
29, Figure 29: Illustrative Example SPM(600): Case 0 -Variation in the fluid flow rates through the upstream conduit (5) and downstream conduit (5) with time -Details provided in Table 2 30. Figure 30: Illustrative Example SPM(600): Case P -Variation in pressure (Pu and PD) with time -Details provided in Table 2 31. Figure 31: Illustrative Example SPM(600): Case P -Variation in the volume of stored fluid in the upstream storage area (3) and downstream storage area (4) with time -Details provided in
Table 2
32. Figure 32: Illustrative Example SPM(600): Case P -Variation in the fluid flow rates through the upstream conduit (5) and downstream conduit (5) with time -Details provided in Table 2 33. Figure 33: Illustrative Example SPM(600): Case Q -Variation in pressure (Pu and PD) with time -Details provided in Table 2. PD refers to pressure in the intermediate storage area (700) 34. Figure 34: Illustrative Example SPM(600): Case Q -Variation in the volume of stored fluid in the upstream storage area (3) and intermediate storage area (700) with time -Details provided
in Table 2
35. Figure 35: Illustrative Example SPM(600): Case Q -Variation in the fluid flow rates through the upstream conduit (5) and downstream conduit (7) with time -Details provided in Table 2 36. Figure 36: Illustrative Example SPM(600): Case Q -Variation in the fluid flow rates through the upstream conduit (5), EPB (2), and downstream conduit (7) with time -Details provided
in Table 2
37. Figure 37: Illustrative Example SPM(600): Case R-Variation in pressure (Pu and P0) with time -Details provided in Table 2 38. Figure 38: Illustrative Example SPM(600): Case R-Variation in the volume of stored fluid in the upstream storage area (3) and downstream storage area (4) with time -Details provided in
Table 2
39. Figure 39: Illustrative Example SPM(600): Case R -Variation in the fluid flow rates through the upstream conduit (5) and downstream conduit (7) with time -Details provided in Table 2 40. Figure 40: Illustrative Example SPM(600): Case R -Variation in the fluid flow rates through the upstream conduit (5), EPB (2), and downstream conduit (7) with time -Details provided
in Table 2
41. Figure 41. Illustrative relationship between gas hourly space velocity, GHSV, (m3 hr' m3 (catalyst)), pressure (range 11.2, 14.6, 21.4 atmospheres -labelled on the Figure), and proportion of reactant (CO) converted to products (CB) expressed as equilibrium proportion of reactant remaining (l-CB); Fischer-Tropsch reaction; Catalyst reduced Fe, at 240° C; (67.42 Fe:26.04 FeO: 0.71 Si02:0.65 Cr203; 4.61 MgO; 0.57 K20). (operating temperature range <207° C to >285° C). FBR = Fixed bed reactor; OFR = Oscilating flow reactor; Data Source for operation in a fixed bed reactor: Anderson, RB., Kern, F.S., and Schultz, J.F., 1963.
Kinetics of the Fischer Tropsch synthesis on iron catalysts. US Bureau Mines Bull., 614.
Circles indicate expected CB associated with a conventional reactor. Squares indicate the theoretical C8 associated with this invention. Arrows indicate the directional impact of the invention on C8 relative to a conventional reactor. Cases 0, P, Q, R are for the reactor parameters and cases identified in Tables 2 and 3. Different methods of operating the oscillating flow reactor will give different values of CB for a specific GHSV.
42. Figure 42: Case 0 pressure sensitivity increasing EPB (2) diameter to 1 m 43. Figure 43: Case 0 pressure sensitivity increasing EPB (2) diameter to 2m 44. Figure 44: Case 0 flow rate sensitivity increasing EPB (2) diameter to I m 45. Figure 45: Case 0 flow rate sensitivity increasing EPB (2) diameter to 2m 46. Figure 46: Case 0 pressure sensitivity upstream storage area (3) volume 0.3 m3; EPB (2) diameter = 2m 47. Figure 47: Case 0 flow rate sensitivity upstream storage area (3) volume = 0.3 m3; EPB (2) diameter 2m 48. Figure 48: Case 0 pressure sensitivity upstream storage area (3) volume 2 m3; EPB (2) diameter = 2m 49. Figure 49: Case 0 flow rate sensitivity upstream storage area (3) volume 2 m3; EPB (2) diameter 2m 50. Figure 50: Case 0 pressure sensitivity upstream storage area (3) volume 5 rn3; downstream storage area (4) volume 4 m3; EPB (2) diameter 2m 51. Figure 51: Case 0 flow rate sensitivity upstream storage area (3) volume 5 m3; downstream storage area (4) volume 4 m3; EPB (2) diameter 2m 52. Figure 52: Case 0 pressure sensitivity upstream storage area (3) volume 5 rn'; downstream storage area (4) volume 40 m3; EPB (2) diameter 2m: 300 second period from startup 53. Figure 53: Case 0 flow rate sensitivity upstream storage area (3) volume 5 m3; downstream storage area (4) volume 40 m3; EPB (2) diameter 2m: 300 second period from startup 54. Figure 54 Case 0 pressure sensitivity upstream storage area (3) volume = 5 m3; downstream storage area (4) volume 40 m3; EPB (2) diameter 2m: 1000 second period from startup 55. Figure 55 Case 0 flow rate sensitivity upstream storage area (3) volume 5 m3; downstream storage area (4) volume 40 m3; EPB (2) diameter 2m: 1000 second period from startup 56. Figure 56-Plot of CO2 GHSV vs. Proportion of CO2 converted to products (CH + CH0).
60% volume contraction (in the product stream) associated with the feed gases other than N2.
Observed contraction is in the range <30% to >70%. CO2 forms between <0.5% and 16% of total gas feed. Residual gas includes CO (<2%), N2 (<5% to >70%), H2 + CH4 � CH + CXIIY0Z, + minor quantities of H2O, 02 <5%. Operating Temperature 16° C to 35° C; Operating feed gas pressure is between <0.1 MPa and <0.5 MPa; Discharge pressure >0.1 MPa; Catalyst constructed in accordance with GB 0817567.1; GB 0817567.1 catalysts illustrated are Catalyst A (+ symbol), Catalyst C (open triangle symbol), Catalyst E (open square symbol), Catalyst F (solid circle symbol), Catalyst K (X symbol), Catalyst L (solid triangle symbol), Catalyst M (solid square symbol), Catalyst N (solid diamond symbol), Catalyst 0 (open diamond symbol). The lines bracket the observed analyses. They indicate the general interpreted trend, but are not intended to represent limit boundaries. Limit boundaries will change with operating conditions, feedstock, and catalyst. In some circumstances the general trend could show a decreasing CB with increasing GHSV.
57. Figure 57 -Plot of CO2 GHSV vs. Proportion of CO2 converted to products. Sensitivity with 10% volume contraction (in the product stream) associated with the feed gases other than N2.
CO2 forms between <0.5% and 16% of total gas feed. Residual gas includes CO (<2%), N2 (<5% to >70%), H2 + CH4 + CH + CXHYOZ, + minor quantities of H2O, 02 <5%. Operating Temperature 16° C to 35° C; Catalyst constructed in accordance with GB 0817567.1; GB 0817567.1 catalysts illustrated are Catalyst A (+ symbol), Catalyst C (open triangle symbol), Catalyst E (open square symbol), Catalyst F (solid circle symbol), Catalyst K (X symbol), Catalyst L (solid triangle symbol), Catalyst M (solid square symbol), Catalyst N (solid diamond symbol), Catalyst 0 (open diamond symbol). The lines bracket the observed analyses. They indicate the general interpreted trend, but are not intended to represent limit boundaries. Limit boundaries will change with operating conditions, feedstock, and catalyst.
In some circumstances the general trend could show a decreasing CB with increasing GHSV.
58. Figure 58-Plot of CO2 GHSV vs. Proportion of CO2 converted to products. Sensitivity with 0% volume contraction (in the product stream) associated with the feed gases other than N2.
CO2 forms between <05% and 16% of total gas feed. Residual gas includes CO (<2%), N2 (<5% to >70%), H2 + CH4 + + CXHYO, + minor quantities of H20, 02 <5%. Operating Temperature 16° C to 35° C; Catalyst constructed in accordance with GB 0817567.1; GB 0817567.1 catalysts illustrated are Catalyst A (+ symbol), Catalyst C (open triangle symbol), Catalyst E (open square symbol), Catalyst F (solid circle symbol), Catalyst K (X symbol), Catalyst L (solid triangle symbol), Catalyst M (solid square symbol), Catalyst N (solid diamond symbol), Catalyst 0 (open diamond symbol). The lines bracket the observed analyses. They indicate the general interpreted trend, but are not intended to represent limit boundaries. Limit boundaries will change with operating conditions, feedstock, and catalyst.
In some circumstances, the general trend could show a decreasing C5 with increasing GHSV.
EXAMPLE REACTOR STRUCTURE
The essential elements of the invention are incorporated in Figure Ia. This non-limiting section of the specification identifies how the invention can be constructed. This example includes a number of optional features, which can be included to assist or facilitate operability.
E1.O Catalyst Catalyst, or filtrate, or absorbent, or another material, or a combination thereof, may be optionally placed in any vessel or conduit (within the apparatus), or used to line a vessel or conduit wall (within the apparatus), or may be placed at any point within the apparatus. Membranes placed within the apparatus may be coated with catalyst, or impregnated with catalyst, or constructed from catalyst, or a combination thereof One or more catalysts can be entered into the reactor as a fluid, including, but not limited, to gas, liquid, vapour, slurry, fluidised solid, gassified solid, and gassified liquid.
E2.O Reactant The invention is designed to operate with one or more fluids as reactants and one or more fluids as products. One or more reactants can be solid. One or more products can be solid.
E3.O Particle Fields
Some reactions are enhanced by the presence of a magnetic, or electromagnetic, or ultrasonic, or acoustic, or x-ray, or other form of particle field, or another form of wave field or a combination thereof. The presence of these fields at appropriate locations within the invention is specifically incorporated. Non-limiting example applications include the production of biodiesel, production of nano-wires, and the ionisation of reactants to allow the catalytic formation of products.
E.4.O Plant Structure The simplest structure for the invention is illustrated in Figure Ia. During design the principal considerations are: (i) the design and structure of the EPB (2); (ii) the design and structure of the upstream storage area (3) and the downstream storage area (4); and (iii) the design and structure of the pressure management system used in the upstream storage area and the downstream storage area. This example, illustrates various aspect of the invention's construction.
E4.1 Modules The invention can be constructed as one or more modules. The non-limiting boundary (600) of an example module is identified in Figures 2a, 3a, 4a. In accordance with Figure 1 b, more than one EPB (2) can be placed in series. When a module is placed downstream of another module containing an EPB (2) (Figure 2b, 3b, 4b) the conduit (5) is relabelled (10) with an optional control valve (II). When a module is placed upstream of another module containing an EPB (2) (Figure 2b, 3b, 4b) the conduit (7) is relabelled (23) with an optional control valve (24).
Modules are placed in series, or in parallel, or a combination thereof. Each module can be constructed as a skid mounted unit, or a transportable unit, or as a fixed unit. The modules can be constructed on any scale.
E4.1.1 Upstream Storage Area (3) A fluid (34) entering an upstream storage area (3) (Figure 2a), accumulates by displacing a lighter fluid (35), or a heavier fluid ((52), (53) (Fig. 4a)), or a compressible fluid (35). The fluid (34) is separated from the lighter fluid (35) by a fluid-fluid contact (36). As the volume of the fluid (34) increases the volume occupied by the lighter fluid (35) must decrease and vice versa.
The upstream storage area (3) may contain (Figure 2a) more than one vessel (e.g. (14), (16)) arranged in series, or in parallel, or a combination thereof. Conduits (17) can connect the vessels. Optional valves(18) can control fluid flow through these conduits (17). The presence of multiple vessels connected by conduits provides a level of control on the stored volume of the fluid (34).
The upstream storage area (3) can contain a conduit (25) controlled by a valve (26) which is used to add (or remove) fluids or to add a pressure management system (Figure 3a). The lighter fluid (35) can be a gas.
One or more heavier fluids (52), (53) may be present (Fig. 4a) in the upstream storage area (3). These fluids (52), (53) may be reaction products, or separation products, or may be added as a pressure management tool, or may be reactants, or serve another purpose, or a combination thereof. They are added, or removed, from the upstream storage area (3) by one or more conduits (58), (59) controlled by one or more valves (61), (62). Their temperature may be controlled by one or more heat exchangers (64). The heavier fluid (52), (53) is separated from the principal reactant (34) by a fluid-fluid contact (55), (56).
E4.1.2 Downstream Storage Area (4) A fluid (31) entering (Figure 2a) an downstream storage area (4) displaces a lighter fluid (32), or a heavier fluid (54) (Fig. 4a), or a compressible fluid (32). The fluid (31) is separated from the lighter fluid (32) by a fluid-fluid contact (33). Consequently, as the volume of the fluid (31) increases the volume occupied by the lighter fluid (32) must decrease and vice versa.
The downstream storage area (4) may contain (Figure 2a) more than one vessel (e.g. (15), (19)) arranged in series or in parallel or a combination thereof. A vessel containing an EPS (2) and part of the downstream storage area (4) and part of the upstream storage area (3) is labelled (13). Conduits (20) can connect the vessels. Optional valves (21) can control fluid flow through these conduits (20).
The presence of multiple vessels connected by conduits provides a level of control on the stored volume of the fluid (31).
The downstream storage area (4) can contain a conduit (27), (29) controlled by a valve (28), (30) which can be used to add (or remove) fluids or to add a pressure management system (Figure 3a). The lighter fluid (32) can be a compressed gas.
One or more heavier fluids (54) may be present (Fig. 4a) in the downstream storage area (4). These fluids (54), may be reaction products, or separation products, or may be added as a pressure management tool, or may be reactants, or serve another purpose, or a combination thereof. They are added or removed from the downstream storage area (4) by one or more conduits (60) controlled by one or more valves (63). Their temperature may be controlled by one or more heat exchangers. The heavier fluid (54) is separated from the principal reactant (31) by a fluid-fluid contact (57).
E4.1.3 Heating Optionally one or more heat exchangers (e.g. (12), (22), (64) (Fig. 4a)) can be placed at any location within the upstream storage area (3), downstream storage area (4), EPB (2), upstream conduit (5) and downstream conduit (6). These heat exchangers can be used to adjust temperatures within the reactor in order to assist a catalytic (or non-catalytic reaction) reaction, or enhance (or prevent) a separation (or adsorption, or desorption or precipitation or filtration) process, or alter fluid viscosity, or alter one or more of P, PL, and PD, or a combination thereof.
E4.1.4 Fluid Management System The volume change (when the reactant is a liquid) is accommodated by using a compressible fluid, or displaceable fluid. Figure 3a, 4a illustrate a non-limiting example where the conduits (25), (27) are able to receive additional fluids (or remove fluids) through one or more conduits (e.g. (39), (40), (43)) controlled by one or more valves (e.g. (9), (41), (42), (44), (45), (49)). One or more expansion vessels (e.g. (37), (38)) may be present on these conduits. One or more fluids may be used to control the pressure in these vessels (e.g. (35), (46), (32), (50)). The fluids may be separated by fluid-fluid contacts (e.g. (47), (51)). The structures illustrated in Figures 3a and 4a also illustrate that the reactant fluid can be separated into two or more fluids within the upstream storage area (3), or downstream storage area (4), or combination thereof, and that each fluid can be directed to one or more separate conduits. A membrane separator can be used to replace, or supplement one or more of these conduits.
E4.2 Example Pressure Management: Gas Feed The structures illustrated in Figures Ia, Ib, 2a, 3a, 4a can be used with a gas feed. The optional pressure management system illustrated in Figures 3a and 4a can be absent, or may be used with a displaceable liquid fluid. Condensed or precipitated liquids may be collected and removed from the upstream storage area (3) or downstream storage area (4). An optional pressure management system may be attached to the optional conduits (58), (59), 60). The upstream storage area (3) and downstream storage area (4) may only contain gas. Pu increases as the volume of gas stored in the upstream storage area (3) increases. PD increases as the volume of gas stored in the downstream storage area (4) increases. Cyclically altering the rate of P and/or PD increase, or decrease, cyclically alters LP.
E4.3 EPB (2) Structure The function of the EPB (2) is to assist in cyclically altering the flow rate between the upstream storage vessel (3) and the downstream storage vessel (4). This allows the EPB (2) to be structured as a rigid permeable, or porous and permeable membrane, or a displaceable fluid, or a particle bed, or a combination thereof. In some embodiments of the invention, the principal control on flow will be active (or passive) management of iW, P and P. In other embodiments, the principal control on flow will be changes in k in the EPB (2) in response to actively managed or passively managed changes in iSP, Pu and PD. Both types of EPB (2) can be combined within a reactor.
Within each flow cycle, the maximum flow rate through the EPB (2) is greater than the average flow rate into the upstream storage area (3) (through the upstream conduit (5)) and the minimum flow rate through the EPB (2) is less than the average flow rate into the upstream storage area (3). The lower flow rate can be 0 m3 s'. All structural embodiments of an EPB (2) which meet these two requirements are specifically incorporated.
E4.3.1 EPB (2) Structure: Fluid Displacement Module The EPB (2) can be structured as a fluid displacement module, or when more than one EPB (2) is present (e.g. Figure Ib) a fluid displacement module can be placed upstream, or downstream of an EPB (2) in order to create a travelling pressure wave through the EPB (2).
The illustrative boundary of the fluid displacement module is labelled on Figure 5 as (603). The module (603) is constructed as a vertical or inclined pair of vessels (e.g. (78), (80)) connected by a conduit (79). Each vessel (e.g. (78), (80)) is connected to one or more expansion vessels (e.g. (74), (84)) by one or more conduits (e.g. (77), (83)). Optionally the vessels are connected to a recipient vessel (68) and a discharge vessel (88) by one or more conduits (e.g. (73), (87)). The central carrier conduit (CCC) (66) discharges a fluid (65) into one or more recipient vessels (68) or the conduit (73), (77) or the vessel (78). Fluid (65) is discharged from the conduit (83), (87) or one or more discharge vessels (88) through a CCC (93). The vessels (e.g. (78), (80)) contain a displaceable fluid (95) with fluid-fluid contacts (96) and (97). Each vessel (e.g. (68), (78), (80), (88)) optionally has one or more conduits (e.g. (69), (70), (75), (81), (85), (89), (90)), controlled by valves (e.g. (71), (72), (76), (82), (86), (91), (92)), which are used to add or remove fluids, or are connected to a pressure control vessel containing a compressible fluid, or a pressure management system. One or more optional heat exchanger (e.g. (98), (99), (100)) may be used to control the temperature of the fluids. The pressure wave is created by the cyclic displacement of the dense fluid (95). The pressure exerted by the fluid (65) increases gradually with time until the fluid (65) is able to displace the fluid (95). At this point pressure release occurs and the fluid (65) flows from the vessel (78) into the vessel (80). Following pressure release accompanied by the flow of the fluid (65), the pressure in the upstream vessel (78) is reduced and the fluid barrier (95) reforms. At this point, the flow of fluid from the upstream vessel (78) to the downstream vessel (80) ceases.
This creates a spiked pattern fluid flow where longer periods of no flow (through the EPB (2)) are followed by shorter pulses of high flow. A fluid based pressure management system similar to that illustrated in Figure 3a, 3b, 4a, 4b (vessels (16, (19)) can be optionally used in one or more of vessels (68), (78), (80), (88). The pressure management system can be based on a displaceable fluid, or a displaceable gas or a compressible gas, or a combination thereof.
In some embodiments the displaceable fluid (95) will be the EPB (2). In this situation the upstream storage area (3) contains the vessels labelled (68) and (74), the upstream, conduit (5) contains the conduit and valve labelled (66), (67), the downstream conduit (7) contains the conduit and valve labelled (93), (94), the downstream storage area (4) contains the vessels labelled (84) and (88), and the EPB (2) contains the vessels (78), (79), (80).
E4.3.2 EPB (2) Structure: Particulate EPB There is no preferred method of placing particulate matter in an EPB (2). A non-limiting example is illustrated in Figure 6 where a number of EPB (2) are placed in parallel within a module labelled (601).
The particulate material is labelled (416). The example illustrates three different arrangements for the unit labelled (13) in Figure 2a. This unit is labelled (400), (401), (402) in Figure 6. Each unit is arranged in parallel and is connected via a conduit (e.g. (409)) controlled by a valve (e.g. (410)) to a central carrier conduit (411). The central carrier conduit (411) is an alternative embodiment of the optional conduit (20) illustrated in Figure 2a. The fluid temperature in the central carrier conduit (411) may be controlled by optional heat exchangers (e.g. (413)).
Each unit ((400), (401), (402)) receives feed from one or more conduits (403), (404), controlled by valves (405), (406). These conduits represent an alternative embodiment of the optional conduit (17) illustrated in Figure 2a. The fluid temperature in these conduits ((403), (404)) may be controlled by optional heat exchangers (e.g. (407), (408)). Each unit ((400), (401), (402)) contains a retaining screen (415), or membrane (415), or another method of preventing the particles moving into the conduits (409), or a combination thereof. Each unit ((400), (401), (402)) contains a retaining screen (421), or membrane (421), or another method of preventing the particles moving into the conduits (403), (404), or a combination thereof.
Each EPB (2) can be a sealed unit, or may contain a method (Or apparatus) which can be used to add or remove particulate matter (416). An access point (414) may be provided to allow particulate matter (416) to be added. Alternatively, the particulate matter (416) may be added or removed from the unit as fluidised particulate matter. This is optionally facilitated by fluid conduits (422), (423) controlled by valves (424), (425) where the fluid conduits enter the EPB (2) at locations between the particle movement control points, (e.g. screens (415) and (421)). In some operating environments, the particle bed (416) may require periodic cleaning, or activation, or require some other type of chemical alteration. Accordingly, in some embodiments conduits (e.g. (417), (418)) controlled by valves (419), (420) are used to deliver and remove the cleaning or activation fluids. In some embodiments the particle bed may be fluidised during this operation. The illustrated structure in Figure 6, contains three EPB's (2) arranged in parallel, and allows each individual EPB (2) to be taken off line for either particle replacement, activation, cleaning or another process while the other EPB (2)'s remain on line.
In some processes, there may be a benefit in recycling fluids within the EPB (2), or selectively removing fluids from the EPB (2), or catalytically altering the fluids using one or more catalysts, or proactively altering P and PL, either side of the particle bed (416), or a combination thereof.
Accordingly, one or more conduits (426) optionally controlled by one or more valves (427) can be used to move fluids from an area upstream of the particle bed (416) to an area located downstream of the particle bed (416) or vice versa. This operation can be controlled by a pump (428), or compressor (428), or blower (428), or exhauster (428), or another apparatus designed to move fluids from one location to another (428). The temperature of the fluids in the conduit (426) is optionally controlled by one or more heat exchangers (429). An optional membrane (430) or a membrane (430), (or other form of separator (430)) can be used to remove one or more fluids from the circulating fluid through a conduit (431) controlled by a valve (432). Alternatively a catalytic membrane (430) can be optionally used to add one or more reactants through a conduit (431) controlled by a valve (432). The circulating fluid in conduit (431) can be passed into one or more catalytic reactors (433) before being returned to the reactor.
In some embodiments, it is advantageous to undertake the operation in the presence of a particle or energy field. For example, the catalytic process for the production of biodiesel can be enhanced by the use of ultrasound. Similarly, some catalytic processes can be enhanced by the presence of an electromagnetic or magnetic field. Accordingly, the optional presence of equipment ((437),(438)), or apparatus((437),(438)), or a method designed to assist in undertaking the operation in the presence of a particle field, or energy field ((437),(438)), or a combination thereof, is specifically incorporated.
One or more optional membranes (434) located on the central carrier conduit (411) can be used to add or remove fluids through a conduit (435) controlled by a valve (436). The optional membrane (434) can contain a catalyst.
E4.3.3 EPB (2) Structure: Membrane EPB There is no preferred method of placing a membrane in an EPB (2). A non-limiting example is illustrated in Figure 7 where a number of EPB (2) are placed in parallel in a module labelled (602). The membrane is labelled (522). The example illustrates three different arrangements for the unit labelled (13) in Figure 2a. This unit is labelled (500), (501), (502) in Figure 7. Each unit is arranged in parallel and is connected via a conduit (e.g. (509)) controlled by a valve (e.g. (510)) to a central carrier conduit (511). The central carrier conduit (511) is an alternative embodiment of the optional conduit (20) illustrated in Figure 2a. The fluid temperature in the central carrier conduit (51 1) may be controlled by optional heat exchangers (e.g. (513)).
Each unit receives feed from one or more conduits (503), (504), controlled by valves (505), (506).
These conduits represent an alternative embodiment of the optional conduit (17) illustrated in Figure 2a. The fluid temperature in these conduits ((503), (504)) may be controlled by optional heat exchangers (e.g. (507), (508)).
Each unit ((500), (501), (502)) may optionally contain membrane conduits which allow fluids to flow through the unit (520), (523) and other conduits (521), (524), which allow another fluid to be added to or removed from the EPB (2). Fluids can optionally be added to, or removed, from a membrane unit through one or more conduits (514), (517), (51 8) controlled by one or more valves (51 5), (516), (519).
This provides a method or mechanism, which can be used to alter iW and alter the composition of the fluid in the upstream storage area (3) relative to the composition of the fluid in the downstream storage area (4).
In some embodiments, it is advantageous to undertake the operation in the presence of a particle or energy field. Accordingly, the optional presence of equipment ((437), (438)), or apparatus((437),(438)), or a method designed to assist in undertaking the operation in the presence of a particle field, or energy field ((437),(438)), or a combination thereof, is specifically incorporated.
E4.3.4 EPB (2) Structure: Particulate EPB, Horizontal Orientation Figure 8 illustrates an embodiment containing a horizontal particulate EPB (2). The EPB (2) contains (Figure 8) a permeable retaining screen (900) separating a fluid reception area (901) from the main body (902) of the EPB (2). The retaining screen (900), or membrane (900), or method (900) is structured to prevent particles within the main body (902) entering the fluid reception area (901). The main body (902) is filled with particles. Fluid is removed from the EPB (2) through a fluid departure area (903) which is separated from the main body of the EPB (2) by a permeable retaining screen (904). The combination of a retaining screen and a fluid reception area (e.g. (900), (901)) can take any form and may be a segregated area of the EPB (2) as shown in Figure 8 or may be a conduit. The combination of a retaining screen and a fluid departure area (e.g. (903), (904)) can take any form and may be a segregated area of the EPB (2) or may be a conduit as shown in Figure 8.
The particulate material (905) can fill the entire volume of the main body (902) or may fill part of the main body (as illustrated in Figure 8). In this instance fluid (906) from the fluid reception area (901) or a product fluid, or a combination thereof, may be present in the main body (902) above the particle bed (905) and a particle-fluid boundary (907) may be present. The EPB (2) contains one or more fluid reception areas (901) and one or more fluid departure areas (903). Part, or all of each retaining screen (900), (904) is permeable. The retaining screen (904) associated with the fluid departure area (903) may be confined entirely within the particle bed (905). Apparatus (908), or a method, or a vessel, or vessel design may be used to ensure that the retaining screen (904) is always located within the particle bed (905). The fluid reception area (901) is fed by one or more conduits (17). The fluid departure area (903) discharges its fluid into one or more conduits (20).
E4.4 EPB (2) Structure: Permeability The principal function of the EPB (2) is to assist in the creation and maintenance of a cyclically changing pressure differential between the upstream storage area (3) and the downstream storage area (4) in order to increase the catalyst contact time, or reactant contact time, or fluid separation times, or a combination thereof. The cross-sectional pore area in the EPB (2) may be less than, or greater than, or equal to the cross sectional area of the central upstream volume (14) or the central downstream volume (15). The EPB (2) is constructed from particles, or one or more membranes, or a combination thereof, as one or more of:- (I) A membrane or porous and permeable medium where the intrinsic permeability, k, remains constant as P varies (ii) A membrane or porous and permeable medium where the intrinsic permeability, k, remains constant as iW varies, but a minimum value of /.W, (i.e. PM) is required in order to initiate viscous flow (iii) A membrane or porous and permeable medium where the intrinsic permeability, k, increases as P increases (iv) A membrane or porous and permeable medium where the intrinsic permeability, k, increases as P increases, but a minimum value ofP, (i.e. PM) is required in order to initiate viscous flow (v) Particulate material where the intrinsic permeability, k, remains constant as iW varies.
Figure 9 illustrates over the time interval 0 to 20 minutes, increasing Q associated with a constant k and increasing P. (vi) Particulate material where the intrinsic permeability, k, remains constant as iW varies, but a minimum value of iW, (i.e. PM) is required in order to initiate viscous flow. Figure 9 illustrates over the time interval 0 to 20 minutes a period of low permeability flow is followed by an abrupt increase in Q (and k) at 20 minutes when P = PM and flow switches from diffusion flow to viscous flow. Q then gradually increases (in unexpanded porosity) as k remains constant, iP increases, and �sP > M over the time interval 20 to 35 seconds.
(vii) Particulate material where the intrinsic permeability, k, increases as AP increases. The increase in k may be associated with an increase in porosity. Figure 9 illustrates over the time interval 30 to 120 minutes, a situation where i\P > PM and flow cyclically switches from flow in unexpanded porosity, to flow in expanded porosity where k increases as tP increases, before the porosity collapses as iW reduces and flow returns to flow in unexpanded porosity. Variations of this pattern are illustrated in Figures 10, Il and 13.
(viii) Particulate material where the intrinsic permeability, k, increases as tP increases, but a minimum value of i\P, (i.e. PM) is required in order to initiate viscous flow. The increase in k may be associated with an increase in porosity. Figures 12 and 15 illustrate an example where flow oscillates between diffusion flow (intra-particle flow) and viscous flow (inter-particle flow) in expanded porosity. This example illustrates a situation where k, increases as i\P increases, but a minimum value ofP, (i.e. PM) is required in order to initiate viscous flow. Figure 14 illustrates an example where flow oscillates between diffusion flow and viscous flow in expanded porosity. In the example illustrated in the Figure 14 example, major flow cycles switch between diffusion flow and flow in expanded porosity. Minor flow cycles are between unexpanded porosity and expanded porosity within a viscous flow environment.
An EPB (2) can be constructed to include a combination of these features. The EPB (2) can be constructed to include more than one abrupt change in k as.P increases or decreases. The EPB (2) can be constructed with only one abrupt change in k as zP increases or decreases (e.g. a switch from Knudsen Diffusion to viscous flow).
This versatility allows the EPB (2) to be constructed on a nano-scale or a macro-scale for different types of applications.
The pressure wave travelling through the EPB (2) is constructed by (i) adjusting the flow of fluids into and out of the upstream storage areas (3) and downstream storage areas (4) (e.g. Figures 1 to 4), or (ii) constructing the EPB (2) to change permeability as a function of iSP, or (iii) adjusting the elevations of the fluid-fluid contacts (e.g. (36), (33) (47), (51)) located in the upstream storage areas (3) and downstream storage areas (4), where a displaceable fluid, or a compressible fluid, or a combination thereof, overlies a fluid (e.g. (31), (34)) (e.g. Figures 1 to 4), or (iv) adjusting the pressure associated with compressible fluids located in the upstream storage areas (3) and downstream storage areas (4) (e.g. Figures 1 to 4), or (v) adjusting the density, viscosity, temperature and volume of a displaceable fluid (95) fluid designed to modulate the upstream potential energy (e.g. Figure 5), or (vi) adjusting the permeability, density, particle size, particle shape and volume of a particle bed EPB (2), or (vii) adjusting the pressure in a membrane EPB (2) through the addition or removal of fluids, or (viii) adjusting the hydrostatic (fluid pressure) in a flexible membrane where the outer annulus (e.g. (521), (524)) is not in fluid communication with the inner annulus (e.g. 520), (523)) and changing the fluid pressure in the outer annulus (e.g. (521), (524)) results in a change in the permeability in the inner annulus (e.g. 520), (523)) or (ix) using pumps/compressors and pressure wave generators to cyclically vary P or (x) by using a combination thereof.
These pressure management features allow a pressure wave to be created with any shape, form, amplitude, duration and repeat frequency.
OPERATING EXAMPLES
The operation and characteristics of the invention are illustrated through a number of non-limiting
examples.
Example 1: Flow Patterns through the EPB (2) The invention operates by cyclically altering the flow rate through the EPB (2). When designing a particulate EPB (2), the critical parameters (for a specific particle size/type, and constant feed flow rate and feed flow pressure) are the diameter of the particle bed and the length of the particle bed. Other variables can include flow rate and particle bed permeability.
Example 1, Cases A to L, (Table I, Figures 9 to 20) illustrate the flow patterns associated with the invention and demonstrate how the flow patterns can be changed by adjusting the EPB (2), (i.e. adjustments to EPB (2) diameter and length), particle bed permeability, and the constant flow rate delivered to the upstream storage area (3).
The behaviour of the same particulate material in a conventional packed bed reactor (Case M, Figure 21) and conventional fluidised bed reactor (Case N, Figure 23) illustrates that in both cases, the flow rate builds to a constant value and does not vary with time. These examples also demonstrate (Figures 22, 24), that the invention operates with a lower internal pressure than either a fixed bed reactor, or a fluidised bed reactor.
Table 1: Examples of Flow Patterns through the EPH (2) where the fluid in the upstream storage area is a non compressible fluid F = flow rate, (m3 mm') entering the reactor through the upstream conduit (4); EPB (2) is constructed as a particle bed; The intra-particle permeability 6.12 l0' m3 m2 s' Pa1; k= Al -inter-particle permeability = 3.28 10' m3 m2 s' Pa'; k= A2 -inter-particle permeability 3.28 10 m3 m2 s' P1' k= A3 -inter-particle permeability 3.28 10'' m3 m2 s' Pa'; (C) particle bed constrained to ensure that particle bed expansion cannot occur (i.e. reactor behaves as a fixed bed reactor); EPB (2): Diameter Im; Static particle bed height lm; Particle size = 1 mm; Particle Density 2.65 t m3; Inter-Particle Porosity = 50%; Fluid Density = it m3; Fluid viscosity 0.001 Pas; PM = 5000 Pa; tIPF = 8091 Pa; APFIUId = 19,951 Pa; Expanded porosity at the point of fluidisation 70%; Fluidised permeability = 5.1 10 m3 m2 s1 P1'; ED is a measure of the pressure difference across the EPB (2) and driving force zP and is expressed in metres for a fluid density of I t m3 where I m represents a driving force of 10,000 Pa. Length = height of the particle bed column. In this example, the particles are structured with a low intra-particle permeability. When tP exceeds PM flow switches to inter-particle permeability, when iP exceeds flow switches to flow through expanded porosity. When P exceeds IPFlujd flow switches to fluidised flow. This structure allows the particle bed to demonstrate the cycling of flow between inter-particle flow and fluidised flow and the cyclic of flow within expanded porosity and unexpanded porosity.
Case F ED EPB (2) Diameter Length Figure: Comment Oscillating Flow Reactor A 0.02 0.80-0.85 m l.Om kAl l.Om Figure 9-cyclic oscillating flow between flow in expanded porosity and flow in unexpanded porosity B 0.02 0,82-0.85m 1.13 m kAl l.Om Figure 10-cyclic oscillatingflow between flow in expanded porosity and flow in unexpanded porosity C 0.02 0.76-0.86 m 0.8 m k= Al 1.0 m Figure II -cyclic oscillating flow between flow in expanded porosity and flow in unexpanded porosity D 0.02 0.01 -1.25 m 0.2 m k Al 1.0 m Figure 12-cyclic oscillating flow between intra-particle (diffusion) flow and flow in expanded porosity E 0.10 0.76-0.93 m I m k= Al 1.0 m Figure 13-cyclic oscillating flow between flow in expanded porosity and flow in unexpanded porosity F 0.80 0.01 -1.72 m I m k= Al 1.0 m Figure 14 -cyclic oscillating flow in expanded porosity and cyclic flow between flow in intra-particle porosity (diffusion) and flow in expanded porosity G 2.0 Q.04-2,60m 1 m kAl 1.Om Figure 15-cyclicoscillatingflow between intra-particle flow (diffusion) and flow in expanded porosity Fl 0.01 0.82-0.84m I m kAl l.Om Figure l6-cyclicoscillatingflowin expanded porosity with some time intervals exhibiting a constant flow rate 0.02 0.40-0.54 m I m k Al 0.5 m Figure 17-cyclic oscillating flow between flow in intra-particle porosity (diffusion) and flow in expanded porosity.
J 0.02 1.47 -1.67 m I m k Al 2 m Figure 18 -flow in unexpanded porosity is the dominant flow type with pressure release through the episodic expansion of the porosity.
K 0.02 0.01 -0.54 m I m k= A2 Im Figure 19-Oscillation between diffusion flow and flow in expanded porosity L 0.02 0.80 -0.85 1 m k= A3 I m Figure 20 -Oscillation between flow in unexpanded porosity and flow in expanded porosity Existing Fixed Bed (Packed Bed) Reactor M 0.02 2.7m I m kAl I m(C) Figure2l -Thisexarnpleshouldbe compared with the base case (Case A (Figure 9)) and represents the situation associated with a fixed bed reactor. In a fixed bed Q increases until Qk iW. Q then remains constant. Figure 22 illustrates the effective difference in maximum pressure in the upstream storage area (3) as a function of time in the fixed bed reactor (Figure 21) and the oscillating flow reactor (Figure 9).
Existing Fluldised Bed Reactor N 0.02 2.54 m 0.lm k = Al I m Figure 23-This example should be compared with the base case (Case A (Figure 9)) and represents the situation associated with a fluidised bed reactor.
In a fluidised bed Q increases until Q=k AP. Q then remains constant. Figure 24 illustrates the effective difference in maximum pressure in the upstream storage area (3) as a function of time in the fixed bed reactor (Figure 23) and the oscillating flow reactor (Figure 9).
Example 2: Impact of Channelling The operation of the Oscillating Flow Reactor when channelling, or macropore, or piping flow occurs in a particulate EPB (2) is demonstrated in Figure 25. The cyclic flow switches from flow in unexpanded inter-particle (IPF) to flow through macropores/pipes (MF) to flow through fluidised (expanded) inter-particle-porosity (FF) before the flow rate collapses and flow resumes through unexpanded inter-particle porosity (IPF). Fluidisation has the effect of removing the channels/macropores/pipes. Fluidisation collapse has the effect of remaking the particle bed. The length of each oscillating flow cycle varied between cycles and the amount of time spent in each part of the cycle varied between cycles (Figure 26).
Experimental details: SPM(600) module constructed containing a particulate EPB (2), 0.02 m diameter, 0.05 m high, with an expansion chamber 0.15 m high, containing 1 mm diameter quartz particles (2.71 t m3 density) with no intra-particle porosity, average EPB (2) unexpanded inter-particle porosity 28%.; fluid (34) density 998 kg m3; temperature 20 -25 C; fluid (34) is non compressible; fluid (35) is compressible.
Example 3: Pressure Wave Associated with Compressible Fluids Example 1 has illustrated the variation in the flow rate through the EPB (2) in the oscillating flow reactor. The variation in fluid volumes and pressures with time in the upstream storage area (3) and downstream storage area (4) is illustrated, using a compressible fluid, with reference to some specific, but non-limiting assumptions (Case 0 to Case R, Table 2). Each example shows the operation of the reactor from start up.
Case 0: This example maintains: (i) different cyclic oscillating pressures in the upstream and downstream storage areas (Figure 27). The difference in volume between the two storage areas results in a dampening of pressure variation in the downstream storage area (4); (ii) similar levels of fluid storage volume in the upstream and downstream storage areas (Figure 28). The cyclic decreases in fluid storage volume in the upstream storage area (3) correspond to cyclic increases in the fluid storage volume in the downstream storage area (4). The stored gas volumes are expressed at I atmosphere pressure and 00 C; (iii) Fluid volumes entering the reactor (Figure 29) through the upstream conduit (5) stabilise (once the reactor has achieved its equilibrium volumes and pressures) to a constant oscillating flow rate. These inflow oscillations reflect the oscillating flow through the EPB (2) resulting in a continual change in P. Fluid volumes leaving the reactor (Figure 29) through the downstream conduit (7) stabilise (once the reactor has achieved its equilibrium volumes and pressures) to a constant oscillating flow rate. These inflow oscillations reflect the oscillating flow through the EPB (2) resulting in a continual change in P0. By way of contrast, an existing fixed bed reactor fluidised bed reactor will show no oscillations in storage volume, pressure or fluid flows entering, or leaving, the reactor.
Case P: In an oscillating flow reactor, the magnitude of the oscillations can be increased, by increasing the differential between the flow rates in expanded porosity and the flow rates in unexpanded inter-particle or intra-particle porosity. This is illustrated by increasing the fluidisation permeability of the EPB (2) to 10 m3 m2 s Pa'. The impact of this structural EPB (2) change is to increase the degree of oscillation associated with pressure, storage volume and flow rates. In this non-limiting example increasing the fluidisation permeability results in: (i) a similar pressure (Figure 30) in the upstream storage area (3) and downstream storage area (4); (ii) a substantially greater volume (Figure 31) of stored fluid in the downstream storage area (4); and (iii) a greater variation in flow oscillation (Figure 32) in the downstream conduits (7) and upstream conduits (5). In this example, increasing the fluidisation permeability also has the effect of increasing the stabilised throughput of the reactor from around I m3 s' (Figure 29) to around 2.5 m3 s (Figure 32). The example demonstrates that the EPB (2) structure can be used to control the SV in the reactor and that adjustments to the EPB (2) permeability can be used to alter C and sweep efficiency.
Case Q: In some processes, it is desirable to use a rigid membrane or a packed particulate bed EPB (2) for a catalytic process. For example, a coated or impregnated surface, or a complex rigid membrane containing a specific degree of pore tortuosity and a specific pore radii. A pressure wave can be created upstream or downstream of the catalyst bed. Figure lb illustrates that in this situation the first (or the second) EPB (2) can be a rigid EPB (2) while the second EPB (2) can have a porosity and permeability that changes with Pu and P0 (e.g. Cases 0 and P) or can be a displaceable fluid (e.g. Figure 5). This example considers the invention structured in accordance with Figure Ib, where the first EPB (2) is a rigid membrane and the second EPB (2) is a displaceable fluid column with a column height of 5 m and a recovery time of I second. In this example, there is a cyclic oscillation of pressure (Figure 33) in the storage areas. There is also a cyclic variation in storage volume (Figure 34). Flow into the reactor through the upstream conduit (5) shows only minor variations with time (Figure 35), while the impact of the displaceable fluid EPB (2) is to create a spiked flow pattern (Figure 35) in the downstream conduit (7). The flow rate across the rigid EPB (2) is illustrated in Figure 36. In this example (Figure 36) the rigid EPB (2) acts as a dampener, reducing the effect of the flow oscillation in the downstream conduit (7) on flow into the reactor through the upstream conduit (5).
Case R: The reactor can be structured in accordance with Figure Ia and have a rigid membrane or packed bed as a EPB (2). It is however, a requirement that a method of creating a cyclic pressure wave across the EPB (2) exists. Cyclic adjustments to the downstream valve (8) (or another pressure modulating apparatus) can be used to induce a cyclic pressure wave through the EPB (2). A non-limiting example is illustrated in Figures 37 to 40.
Table 2: Examples of Flow Patterns through the EPB (2) where the fluid in the upstream storage area is a compressible fluid Feedstock: compressible gas, e.g. 2H2:ICO; Pressure in upstream conduit (5) 30 bar; Pressure in downstream conduit (7) 2 bar; EPB (2) is constructed from particulate material where the intra-particle/inter-particle permeability is l0' m3 m2 s1 Pa' and the fluidisation permeability is m3 m 2 s_I Pa'; EPB (2) diameter = 0.3 m; APFIUId = 17.6 bar; Upstream conduit (5) permeability 1.79 10.6 m3 s' Pa'; Downstream conduit (7) permeability = 1.79 10 m3 s Pa'; Upstream Storage Area (3) Volume I m3; Downstream Storage Area (4) Volume = 4 m3. Distance between the sieves/membranes (415) and (421) is >1.7 m; Sd = standard deviation; DSC = downstream conduit (7), USC = upstream conduit (5), USA = upstream storage area (3); DSA = downstream storage area (4), EPB elastic permeable barrier (2). P = driving force; In this example the temperature is the same in the USA(3) and DSA(4). In some embodiments the temperatures in the USA(3) and DSA(4) will be different.
A. Fluid Discharge, m3 s' Case USC(S) EPB (2) DSC(7) Mean Sd Mean Sd Mean Sd O 0.9 0.073 0.9 0.579 0.9 0.018 P 2.46 0.155 2.46 5.49 2.46 0.192 Q 1.55 0.03 1.55 0.26 1.55 1.55 R 0.35 0.09 0.35 0.21 0.35 1.22 B. Pressures (MPa) Case USA(3) DSA(4) or (700) P across EPB (2) Mean Sd Mean Sd Mean Sd o 2.496 0.0406 0.701 0.0103 1.794 0.0501 P 1.621 0.0866 1.580 0.1074 0.041 0.107 Q 2.128 0.017 1.908 0.025 0.222 0.037 R 2.773 0.050 2.7 17 0.062 0.056 0.030 Example 4: Chemical Significance of the EPB (2) All catalytic reactions show a relationship between flow rate (space velocity or gas hourly space velocity (GHSV)) through the catalyst bed. The general trend is for a decrease in the proportion of reactant (C0) converted to product as the space velocity increases. For a specific space velocity, C8 may also increase as the pressure increases. A typical example is illustrated in Figure 41 (Table 3).
Figure 41 illustrates (as circles) the CBfrom use of the catalyst in a fixed bed or fluidised bed reactor.
Figure 41 also illustrates (as squares) the C8 associated with the oscillating flow rate through the EPB (2) for the situation where for a specific GHSV (gas hourly space velocity), the fluid volume flowing through the EPB (2) on each oscillating flow cycle is less than the fluid volume held in the catalyst bed using the example parameters defined in Table 2. Arrows on Figure 41 indicate the directional impact of the invention.
Table 3. Impact of oscillating flow on fluid residence time in the catalyst bed Parameters: Catalyst is placed in the upstream storage area (3); Example cases are documented in Table 2. Flow rate through the upstream conduit (5) provides the average GHSV expected for a fixed bed catalytic reactor. The oscillating flow results in increased fluid residence time within the catalyst bed (associated with a specific GHSV). This increased fluid residence time in the catalyst bed results in increased catalytic activity and lowers the effective GHSV. The exact impact of oscillating flow on C8 is catalyst specific. The impact of oscillating flow on C8 will vary with the shape and frequency of the P wave. In this example, a feed delivery GI-ISV of 537 provides a C8, which is associated in a fixed bed reactor with a GHSV of 65:19 (the effective GHSV). The effective GHSV is the GHSV (based on constant flow in a conventional reactor) which gives the same C8. In other examples, the oscillating flow may increase, or decrease, the effective GHSV, relative to the fixed bed delivery GHSV where the flow rate through the catalyst bed is constant. The fixed bed GHSV = feed delivery GHSV for an oscillating flow reactor.
Osciflating Fixed Bed Flow Fixed Bed Residence Residence Effective Case GHSV Time, s Time, s GHSV 0 537 3.352 27.61 65.19 P 1462 1.231 4.23 425.64 Q 925 1.947 13.67 131.65 R 240 7.489 68.55 26.26 Example 5: Relationship between Pressure, Flow Rate, and EPB (2) Diameter In an EPB (2) constructed from particulate material a major influence on the range in pressure amplitude (measured from the cycle trough to the cycle peak) in the upstream storage area (3) is the diameter (or surface area) of the EPB (2). Increasing the EPB (2) diameter, while maintaining a constant volume (at STP) in the upstream storage area (3), results in an increase in the variation in both the pressure in the upstream storage area (3) and P. This is illustrated for Case 0 (Table 2) using EPB (2) diameters of 0.3 m (Figure 27), 1.0 m (Figure 42) and 2.0 m (Figure 43).
The increase in pressure variation in the storage areas is accompanied (Figures 28, 44, 45) by an increase in the duration of each pressure amplitude cycle and an associated increase in the variation in the flow rate of fluid into the upstream storage area (3) through the upstream conduit (5).
Figure 43 demonstrates that when the diameter of the EPB (2) exceeds a critical level, the minimum pressure in the upstream storage area (3) during a cycle may correspond to the maximum pressure in the downstream storage area (4) during a cycle.
Example 6: Impact of altering the Upstream Storage Volume (3) The impact of decreasing the volume of the upstream storage area (3) associated with a specific EPB (2) diameter and downstream storage volume (4) is to decrease the duration of each pressure and flow cycle. This is schematically illustrated for a 2 m diameter EPB (2) (Figures 43, 45) and varying the volume of the upstream storage area (3), where the volume is 0.3 m3 (Figures 46, 47); 1 m3 (Figures 43, 45), 2 m3 (Figures 48, 49) and Sm3 (Figures 50, 51). Increasing the cycle periodicity results in an increase in the total volume of fluid discharged from the upstream storage area (3) to the downstream storage area (4) through the EPB (2) during a cycle.
The impact on the example illustrated in Figures 50 and 51 of increasing the storage capacity of the downstream storage area (4) from 4 m3 to 40 m3 is illustrated by Figures 52, 53, 54, and 55.
Increasing the volume of the downstream storage area (4) dampens the flow rate into the downstream conduit (7), reduces the pressure cycle periodicity, reduces the average pressure in the upstream storage area (3) and increases the length of time taken for an equilibrium pattern of flow to develop. The concentration of potential energy in either the upstream storage area (3) or the downstream storage area (4) can be used to facilitate a membrane separation process (e.g. dialysis).
Example 7: Energy Recovery The examples have demonstrated that the invention can focus the kinetic energy into concentrated bursts which are represented by the product flow rate into the downstream conduit (8) or fluid flow into the upstream storage area (3), or a combination thereof. In the example illustrated in Figure 39 and 40, the energy is concentrated in a flow rate which has been changed from a delivery average of around 0.35 m3 s' to a discharge (Q) of 4.6 m3 s' every 13 seconds. The total power (P0) in the fluid can be approximated as P0 = df/2 Q3 F. Where F = the swept rotor area for a turbine (m2); df = fluid density.
In this example (with d1 = 0.000476 t m3) concentrating the fluid discharge as a single pulse 4.6 m3 s' allows 189 times more power to be available for extraction than discharging the same volume at a rate of 0.35 m3 s'. Consequently, the invention can be used to concentrate energy for extraction as motive or electrical power.
Example 8: Carbon Capture There is a requirement to remove carbon oxides (carbon dioxide and carbon monoxide) from waste gases and exhaust (flue) gases from industrial operations. The current focus is on removing the CO2 from the waste gas and injecting it into an aquifer or reservoir for permanent storage (as either a gas or liquefied C02). The required rates of CO2 removal from the flue gases associated with a 300 MW hr coal fired power station are around 20 m3 s'. This increases to around 200 m3 s1 for a 3000 MW hr coal fired power station. The alternative solution is to convert the CO2 into a product. The ionic substance catalyst defined in GBO8 17567.1 allows the CO2 to be converted into one or more hydrocarbon or organic chemical products. i.e. aCO + bCO2 + cCH4+ dH2 + eC0HO + fCH = gCH+ hCOHXOY + iH2 +jH2O (F!) In some circumstances, the ionic catalyst defined in GBO8 17567.1 can be used to produce organic compounds containing N, S and halides. A reactor with the structure illustrated in Figure 8 was constructed. P and PD were continually, and irregularly, varied with time, such that the peak flow rates were greater than the average flow rates. The ionic substance GBO8 17567.1 catalysts examined were Catalyst A, Catalyst C, Catalyst E, Catalyst F, Catalyst K, Catalyst L, Catalyst M, Catalyst N, Catalyst 0. The observed relationship between CO2 GHSV and C is illustrated in Figure 56. The kinetic energy associated with the gas delivery increases as the GHSV increases. These observations (Figure 56) indicate that there is a relationship between GHSV, kinetic energy and C when the catalyst is an ionic substance. This indicates that when the relationship between Pj and PD is continually varied that some of the energy transfer between kinetic energy and potential energy, and vice versa will result in an energy loss where some of the energy is transferred to an ionisation energy (or another form of energy) within the catalyst bed. The presence of this additional ionisation energy (Or other form of energy) will (as illustrated in Figures 56, 57 and 58), when P and P are continually varied, be able to facilitate an enhancement of C with increasing GHSV. This example also demonstrates that the invention can be retrofitted to take flue gas from a power station, without first requiring removal of ash and other particulates.
Example Details: The CO2 content of the gas entering the reactor through the upstream conduit (5) and leaving the reactor through the downstream conduit (7) was measured. Particle bed constructed of catalyst granules <1 mm to >5 mm in diameter; catalyst weight -between 150 and 300 gms. The feed gas composition was constructed in accordance with Claim I GBO8 17567.1. The entry pressure of the gas entering the upstream conduit (5) was maintained within the range 0.1 and 0.3 MPa. The temperature of the gas entering the upstream conduit (5) was maintained between 16 and 350 C. The exit pressure of the downstream conduit (7) was maintained at 0.1 MPa.
Example 9: Carbon Sequestration Sequestration of large volumes of CO2 requires the CO2 to be injected into a reservoir for permanent storage (Metz et al., 2005). Sequestration requires a large reservoir volume. The invention provides a method of increasing the storage capacity of the sequestration reservoir, by allowing the CO2 to be converted at high space velocities to a hydrocarbon/organic chemical product (Figure 56 to 58). This conversion results in volume contraction in the gas. Example 8 (Figure 56 to 58) demonstrates that the proportion of CO2 converted to products in the invention ranges from <10% to >90%. This allows, the overall volume of CO2 injected into the reservoir to be similarly reduced by <10% to >90%. Example 8 demonstrates that a power station with 20 in3 s' CO2 emissions (134 m3 s' total flue gas emission) could achieve a total volume contraction of >50% if the gas was passed through the invention prior to injection into the sequestration reservoir, thereby increasing the storage capacity of the reservoir by >100%. The invention is therefore able to increase the amount of C02, which can be injected into the reservoir.
The embodiments and examples set forth herein are merely illustrative and do not limit the scope of the invention or the details therein. It will be appreciated that many other modifications and improvements to the disclosure herein may be made without departing from the scope of the invention or the inventive concepts herein disclosed, It is to be understood that the details disclosed herein are to be interpreted as illustrative and not limiting in any sense.

Claims (19)

  1. Oscillating Flow Reactor Claims What is claimed is:-I. A process, method and apparatus for the processing of fluids in a reactor where the apparatus contains an elastic permeable barrier, an upstream storage area and a downstream storage area and: i) a driving force is placed across the elastic permeable barrier; this driving force cyclically varies with time and is calculated as the difference between the fluid pressure in the upstream storage area and the fluid pressure in the downstream storage area less any pressure losses resulting from flow through the elastic permeable barrier; ii) the fluid flow rate through the elastic permeable barrier cyclically varies with time and is independent of the flow rate into the upstream storage area through the upstream conduit, or is partially dependent on the flow rate into the upstream storage area through the upstream conduit; iii) the fluid flow rate through the elastic permeable barrier cyclically varies with time and is independent of the flow rate from the downstream storage area into the downstream conduit, or is partially dependent on the flow rate from the downstream storage area into the downstream conduit; iv) part or all of the kinetic energy contained in the fluid entering the upstream storage area through the upstream conduit is transferred into potential energy or another form of energy on entering the upstream storage area; v) part or all of the potential energy contained in the fluid within the upstream storage area is transferred into kinetic energy or another form of energy on entering the elastic permeable barrier; vi) part or all of the kinetic energy contained in the fluid entering the downstream storage area from the elastic permeable barrier is transferred into potential energy or another form of energy on entering the downstream storage area; vii) fluid flow rate cycles have a constant duration, or a variable duration, or an irregular duration; viii) fluid flow through the elastic permeable barrier is continuous, or irregular, or intermittent, or episodic; ix) fluid flow through the elastic permeable barrier oscillates between higher and lower flow rates; the low flow rates can be zero (0) m3 s'; the high flow rates are greater than the average flow rate received by the upstream storage area from one or more upstream conduits.
  2. 2. In accordance with Claim I the apparatus contains one or more upstream conduits controlled by one or more valves; the upstream conduits discharge fluid into one or more upstream storage areas; fluid flows from one or more upstream storage areas into one or more elastic permeable barriers; fluid flows from the elastic permeable barriers into one or more downstream storage areas; fluid flows from the downstream storage areas through one or more downstream conduits controlled by one or more valves; when more than one downstream storage area, or elastic permeable barrier, or upstream storage area or a combination thereof, are present they are arranged in series, or in parallel, or a combination thereof; one or more conduits, or membranes, or a combination thereof, controlled by one or more valves may be present to allow fluids to be added or removed from one or more of the upstream storage area(s), the elastic permeable barrier(s) and the downstream storage area(s); one or more valves can optionally be located at any point within the apparatus.
  3. 3. In accordance with Claims I and 2 the process and apparatus is used to undertake one or more of catalytic reactions, non-catalytic reactions, biological reactions; catalyst, when present, is a fluid, or a solid, or a coating, or a combination thereof; filtrate when present, is a fluid, or a solid, or a combination thereof; absorbent/adsorbent when present, is a fluid, or a solid, or a combination thereof; where: i) solid catalyst, or solid filtrate, or solid absorbent/adsorbent, or solid reactant, or liquid catalyst or gaseous catalyst, or a combination thereof, is placed in one or more of the upstream storage area, elastic permeable barrier, and downstream storage area; ii) the apparatus is constructed as a single module, or as two or more modules; the modules are constructed as permanent structures, or transportable structures, or mobile structures.
  4. 4. In accordance with Claims I to 3 the pressure (measured as potential energy) cyclically varies within each of the upstream storage area, elastic permeable barrier and downstream storage area with time; the potential energy stored in the upstream storage area is greater than, or less than, or equal, to the potential energy stored in the downstream storage area, when the downstream valve is open or partially open, where: i) the potential energy stored in the upstream storage area reduces as the potential energy stored in the downstream storage area increases; ii) the potential energy stored in the downstream storage area reduces as the potential energy stored in the upstream storage area increases; iii) as the potential energy stored in the upstream storage area reduces, the potential energy contained within in the downstream storage area increases; iv) as the potential energy stored in the upstream storage area increases, the potential energy contained within the downstream storage area decreases, or remains constant, or increases at a slower rate.
  5. 5. In accordance with Claims I to 4, the elastic permeable barrier is constructed from one or more of: i) a rigid membrane (or a packed particulate bed) where its permeability does not change with increasing, or decreasing, driving force; the membrane is a porous and permeable membrane, or a permeable membrane, or, ii) a rigid membrane (Or a packed particulate bed) where its permeability changes with increasing, or decreasing, driving force; the membrane is a porous and permeable membrane, or a permeable membrane, or, iii) particulate material placed in a horizontal, vertical or inclined conduit or vessel, where the porosity of the particulate material can be expanded and its permeability increased by increasing the driving force across the elastic permeable barrier; decreasing the driving force results in the permeability of the elastic permeable barrier decreasing and the porosity of the particulate material contracting, or, iv) particulate material placed in a horizontal, vertical or inclined conduit or vessel, where the porosity of the particulate material cannot be expanded and cannot be transferred from one type of porosity to another, or, v) particulate material placed in a horizontal, vertical or inclined conduit or vessel, where the porosity of the particulate material cannot be expanded and can be transferred from one type of porosity to another, or, vi) particulate material placed in a horizontal, vertical or inclined conduit or vessel, where the porosity of the particulate material can be expanded, or contracted; but cannot be transferred from one type of porosity to another, or, vii) particulate material placed in a horizontal, vertical or inclined conduit or vessel, where the porosity of the particulate material can be expanded, or contracted, and can be transferred from one type of porosity to another, or, viii) a membrane, where the permeability of the membrane changes as the driving force across the elastic permeable barrier changes, or, ix) a displaceable fluid (or displaceable solid, or displaceable gel) column placed in two vertical or inclined vessels connected by a connecting conduit or vessel; whereby the displaceable fluid column can be displaced by a pressurised (or compressed) lighter fluid from the upstream conduit or vessel, through the connecting conduit or vessel into the downstream conduit or vessel, to allow the less dense fluid to flow from an upstream location to a downstream location when the driving force exceeds a critical value; decreasing the driving force results in fluid barrier reforming; or, x) a displaceable fluid (or displaceable solid, or displaceable gel) column placed in two vertical or inclined vessels connected by a connecting conduit or vessel; whereby the displaceable fluid column can be displaced by a heavier fluid from the upstream conduit or vessel, through the connecting conduit or vessel into the downstream conduit or vessel, to allow the more dense fluid to flow from an upstream location to a downstream location when the driving force exceeds a critical value; decreasing the driving force results in fluid barrier reforming; or, xi) a combination thereof.
  6. 6. In accordance with Claims I to 5, the flow rate through the elastic permeable barrier cyclically varies with time wherein: i) the duration of each flow cycle is constant or variable; ii) within each flow cycle, the fluid flow rate discharging from the elastic permeable barrier into the downstream storage area, varies from a lower flow rate to a higher flow rate, before returning to a lower flow rate; or from a higher flow rate to a lower flow rate before returning to higher flow rate; iii) the maximum flow rate in each cycle is constant or is variable; iv) the minimum flow rate in each cycle is constant or is variable, and can be zero; v) within each flow cycle the flow rate can assume any wave form; vi) the flow rate through the elastic permeable barrier is a function of the intrinsic permeability of the elastic permeable barrier and the pressure difference, or driving force, across the elastic permeable barrier; vii) the cyclic driving force wave through the elastic permeable barrier can assume any shape, amplitude and frequency, including but not limited to, symmetrical, or asymmetrical, or sinusoidal, or triangular, or harmonic, or Fourier, or square, or spiral, or scroll, or trigger, or a pulse, or a wave train, or another type of wave, or a combination thereof; the driving force wave can be a shock wave resulting from an abrupt change in force level, or an impulsive force, or pulsed force or a combination thereof; the wave form can be damped, or undamped, or underdamped, or overdamped or a combination thereof; the wave amplitude can decline, or increase with time, or may remain constant with time, or a combination thereof; the wave can be a kinematic wave, or a phase wave, or another wave form, or a combination thereof; viii) higher periodicity driving force waves through the elastic permeable barrier may be supplemented with shorter periodicity waves; wave structures can be composite; driving force waves can be supplemented by artificially induced waves associated with ultrasonic equipment, vibration equipment, heating (or cooling) of fluids, or another form of equipment or apparatus; wave periodicity can take any form and can have any duration; ix) the elastic permeable barrier is constructed to allow viscous flow, or Knudsen diffusion, or diffusion, or osmotic diffusion, or a combination thereof; x) the intrinsic permeability of the elastic permeable barrier varies with one or more of fluid type, fluid composition and fluid viscosity; xi) the intrinsic permeability of the elastic permeable barrier can be constructed to allow one or more fluids to change the flow type from Knudsen diffusion (or another form of diffusion flow) to viscous flow and vice versa as the driving force changes; xii) the intrinsic permeability of the elastic permeable barrier can be constructed to allow one or more fluids to change the viscous flow permeability as the driving force changes; the permeability can vary with fluid type; the permeability can be associated with inter-particle flow, flow in expanded porosity, flow in fractures, flow in macropores/pipes/channels; xiii) the intrinsic permeability of the elastic permeable barrier can be constructed to allow one or more fluids to change flow direction in the intra-particle porosity in order to facilitate a cyclic expansion of intra-particle porosity and the contraction of the inter-particle porosity followed by a cyclic contraction of intra-particle porosity and an associated expansion of the inter-particle porosity; xiv) the intrinsic permeability of the elastic permeable barrier can be constructed to allow one or more fluids to change flow direction in the intra-particle porosity in order to facilitate a cyclic contraction of intra-particle porosity and the expansion of the inter-particle porosity followed by a cyclic expansion of intra-particle porosity and associated contraction of the inter-particle porosity; xv) the intrinsic permeability of the elastic permeable barrier changes as the porosity of the elastic permeable barrier expands and contracts or changes from one type of porosity to another or a combination thereof; xvi) the intrinsic permeability of the elastic permeable barrier remains constant or changes with driving force; changes in intrinsic permeability are gradual, or abrupt, or a combination thereof; xvii) the flow rate through the elastic permeable barrier for a specific fluid is calculated as a function of the driving force and the intrinsic permeability; different fluids can flow at different rates through the elastic permeable barrier; the driving force can consider the impact of fugacity; xviii) the fluid flow rates into the upstream storage area are continuous and constant, or continuous and variable, or intermittent, or episodic, or a combination thereof; xix) the fluid flow rate from the upstream storage area via the elastic permeable barrier into the downstream storage area is not continuous and constant; the fluid flow rate is continuous and variable, or is intermittent, or is episodic, or a combination thereof; xx) the fluid flow rate from the downstream storage area into the downstream conduit is continuous and constant, or continuous and variable, or intermittent and constant, or intermittent and variable, or episodic, or a combination thereof; xxi) the fluid is stored in the upstream storage area and the downstream storage area; the volume of fluid discharged through the elastic permeable barrier in each flow cycle is less than, or equal to, the volume of fluid stored in the upstream storage area plus the volume of fluid added to the upstream storage area during the flow cycle; the volume of fluid discharged through the elastic permeable barrier in each flow cycle is less than, or equal to, the available storage volume in the downstream storage area plus the volume of fluid discharged from the downstream storage area during the flow cycle; xxii) the maximum flow rate through the elastic permeable barrier in each flow cycle is greater than the average flow rate entering the upstream storage area through the upstream conduit.
  7. 7. In accordance with Claims 1 to 6, part, or all, of the kinetic energy associated with the fluid entering the upstream storage area, or the elastic permeable barrier, or the downstream storage area, or a combination thereof, is temporarily stored as potential energy as the flow rate through the elastic permeable barrier cyclically decreases.
  8. 8. In accordance with Claims I to 7, part, or all, of the temporarily stored potential energy is converted to kinetic energy within one or more of the upstream storage area, the elastic permeable barrier, and the downstream storage area as the flow rate through the elastic permeable barrier cyclically increases.
  9. 9. In accordance with Claim 7, part of the kinetic energy, when an ionic substance is present, may be converted to, or stored as, ionisation energy.
  10. 10. In accordance with Claim 8, part of the potential energy, when an ionic substance is present, may be converted to, or stored as, ionisation energy.
  11. 11. In accordance with Claims 9, and 10 the stored ionisation energy may be used, when the catalyst is an ionic substance, and the catalysed reaction requires that the covalent reactants or ionic reactants or ionic substances or a combination thereof are ionised, to increase the proportion of reactant converted to products as the space velocity increases.
  12. 12. In accordance with Claims 7 and 8 the cyclic transfer of kinetic energy to potential energy and the cyclic transfer of potential energy to kinetic energy can be used to alter the proportion of reactant converted to products associated with a specific space velocity.
  13. 13. In accordance with Claims 7 and 8 the cyclic transfer of kinetic energy to potential energy and the cyclic transfer of potential energy to kinetic energy can be used to alter the proportion of a fluid removed by a filtrate or absorbent, or a combination thereof associated with a specific fluid flow volume per unit time per unit volume of filtrate or absorbent.
  14. 14. In accordance with Claims 1 to 8 the cyclic transfer of potential energy to kinetic energy can be used to convert dispersed low levels of kinetic energy in the feed fluid entering the reactor through the upstream conduit(s) into a substantial amount of stored potential energy; this stored potential energy can be released over short periods as high levels of kinetic energy or used to assist with fluid separation;
  15. 15. In accordance with Claims I to 14 the sweep efficiency, the proportion of reactant converted to product, and the product selectivity associated with a specific space velocity can be altered by changing the amplitude, periodicity and shape of the travelling driving force wave which passes through the elastic permeable barrier; this alteration in the shape of the travelling driving force wave can, when compared with a catalyst bed with the same space velocity and a constant driving force across the catalyst bed, be used to enhance selectivity for a specific reaction product, or increase the proportion of reactant converted to product, or a combination thereof.
  16. 16. In accordance with Claims Ito 15, alteration of the amplitude, periodicity and shape of the travelling driving force wave which passes through the elastic permeable barrier can be used to enhance (or alter) selectivity for a specific absorbent/adsorption chemical (or desorbent/desorption chemical), or increase (or alter) the proportion of fluid chemicals removed by filtration or absorbent/adsorption (or added to the fluid by desorbentldesorption), or a combination thereof; the enhancement, or increase, or alteration, is compared with the same volume of absorbentladsorbent (or desorbent or filtrate), same fluid space velocity, with a constant driving force across the absorbent (or desorbent or filtrate) bed; fluid space velocity is calculated as ratio of average fluid reactant delivered to the upstream storage area of the reactor (m3 hr'5 to volume of absorbent, or desorbent, or filtrate, or a combination thereof (m3) per unit time;
  17. 17. In accordance with Claims I to 16, alteration of the amplitude, periodicity and shape of the travelling driving force wave, which passes through the elastic permeable barrier can be used to enhance (or alter) selectivity for a specific fluid to be removed through a perm-selective membrane, or increase (or alter) the proportion of fluids removed from the reactor through a perm-selective membrane, or a combination thereof; the enhancement, or increase, or alteration, is compared with the same membrane (where the surface area, composition, porosity, permeability, pore size, pore shape, membrane thickness are identical), same membrane velocity, with a constant driving force across the membrane; membrane velocity is calculated as the ratio of average fluid reactant delivered to the upstream storage area of the reactor (m3 hr') to surface area of the membrane which is in contact with the fluid reactant (m2).
  18. 18. In accordance with Claims I to 17 the reactor can be used to undertake one or more of fluid separation, fluid filtration, heat generation, power generation, energy capture, and fluid absorption/adsorption/desorption, where: i) fluid separation can occur through gravity separation in the upstream storage area, or downstream storage area, or a combination thereof; ii) perm-selective membranes are optionally used to remove (or partially remove) one or more fluids from the upstream storage area, or downstream storage area, or elastic permeable barrier, or a combination thereof; iii) perm-selective membranes are optionally used to add one or more fluids to the upstream storage area, or downstream storage area, or elastic permeable barrier, or a combination thereof; iv) a filtrate or fluid absorbent/adsorbentldesorbent is optionally placed in the upstream storage area, or the elastic permeable barrier, or the downstream storage area, or a combination there of; v) ultrasonic, or electromagnetic, or some other form of field may be applied to the fluids in the reactor in order to facilitate and enhance a catalytic reaction, or a non-catalytic reaction, or a fluid separation process, or a filtration process, or an adsorption/absorption process, or a desorption process, or a combination thereof;
  19. 19. In accordance with Claims Ito 18 the elastic permeable barrier will have different permeabilities for different fluids at a specific driving force, where: i) the permeability (for a specific fluid) decreases with increasing fluid viscosity; ii) the driving force required to switch from diffusion flow to viscous flow through the elastic permeable barrier (when the elastic permeable barrier is structured to allow diffusion flow) varies with fluid type; iii) the driving force required to switch from viscous flow in unexpanded porosity to viscous flow in expanded porosity varies with fluid type; iv) differential permeabilities in the elastic permeable barrier (and flow rates through the elastic permeable barrier) can result in differences in the concentration of the various fluid components in the upstream storage area when compared with the concentration of the same fluid components in the downstream storage area; this attribute of the invention can be used to reduce the relative ratio of backward reactions to forward reactions in a catalytic or non-catalytic equilibrium reaction.
GB0909620.7A 2009-06-04 2009-06-04 Oscillating flow reactor Expired - Fee Related GB2470764B (en)

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB775415A (en) * 1954-10-05 1957-05-22 Commw Scient Ind Res Org Improved method and means for extracting an adsorbable solute from a suspension of finely divided solids in a solution
GB778537A (en) * 1955-01-26 1957-07-10 Kloeckner Humboldt Deutz Ag Improvements in gas filters
GB1296892A (en) * 1969-03-14 1972-11-22
SU787055A1 (en) * 1978-10-09 1980-12-15 Всесоюзный научно-исследовательский институт синтетических смол Continuous extraction method for solid substance-liquid systems
GB2324744A (en) * 1997-04-29 1998-11-04 Canada Majesty In Right Of Pulsed fluidised bed
US6239095B1 (en) * 1998-07-10 2001-05-29 Degussa-Huls Aktiengesellschaft Process for preparation of coated peroxygen compounds

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5922649A (en) * 1982-07-28 1984-02-04 Mitsui Eng & Shipbuild Co Ltd Method for preventing particles from agglomeration on inside wall of gas phase fluidized bed reactor

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB775415A (en) * 1954-10-05 1957-05-22 Commw Scient Ind Res Org Improved method and means for extracting an adsorbable solute from a suspension of finely divided solids in a solution
GB778537A (en) * 1955-01-26 1957-07-10 Kloeckner Humboldt Deutz Ag Improvements in gas filters
GB1296892A (en) * 1969-03-14 1972-11-22
SU787055A1 (en) * 1978-10-09 1980-12-15 Всесоюзный научно-исследовательский институт синтетических смол Continuous extraction method for solid substance-liquid systems
GB2324744A (en) * 1997-04-29 1998-11-04 Canada Majesty In Right Of Pulsed fluidised bed
US6239095B1 (en) * 1998-07-10 2001-05-29 Degussa-Huls Aktiengesellschaft Process for preparation of coated peroxygen compounds

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GB0909620D0 (en) 2009-07-15

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