US20130153188A1 - Advanced smr reactor design featuring high thermal efficiency - Google Patents
Advanced smr reactor design featuring high thermal efficiency Download PDFInfo
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- US20130153188A1 US20130153188A1 US13/327,924 US201113327924A US2013153188A1 US 20130153188 A1 US20130153188 A1 US 20130153188A1 US 201113327924 A US201113327924 A US 201113327924A US 2013153188 A1 US2013153188 A1 US 2013153188A1
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- reactor tube
- heat transfer
- transfer structure
- inside surface
- reactor
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
- C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
- C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
- C01B3/34—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
- C01B3/38—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts
- C01B3/384—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts the catalyst being continuously externally heated
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
- B01J8/02—Chemical 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
- B01J8/0242—Chemical 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
- B01J8/025—Chemical 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
- B01J8/02—Chemical 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
- B01J8/06—Chemical 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 in tube reactors; the solid particles being arranged in tubes
- B01J8/062—Chemical 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 in tube reactors; the solid particles being arranged in tubes being installed in a furnace
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
- B01J2208/00008—Controlling the process
- B01J2208/00017—Controlling the temperature
- B01J2208/00106—Controlling the temperature by indirect heat exchange
- B01J2208/00115—Controlling the temperature by indirect heat exchange with heat exchange elements inside the bed of solid particles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
- B01J2208/00796—Details of the reactor or of the particulate material
- B01J2208/00823—Mixing elements
- B01J2208/00831—Stationary elements
- B01J2208/0084—Stationary elements inside the bed, e.g. baffles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
- B01J2208/06—Details of tube reactors containing solid particles
- B01J2208/065—Heating or cooling the reactor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/30—Details relating to random packing elements
- B01J2219/302—Basic shape of the elements
- B01J2219/30207—Sphere
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/30—Details relating to random packing elements
- B01J2219/302—Basic shape of the elements
- B01J2219/30215—Toroid or ring
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/30—Details relating to random packing elements
- B01J2219/304—Composition or microstructure of the elements
- B01J2219/30408—Metal
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/02—Processes for making hydrogen or synthesis gas
- C01B2203/0205—Processes for making hydrogen or synthesis gas containing a reforming step
- C01B2203/0227—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step
- C01B2203/0233—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step the reforming step being a steam reforming step
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/12—Feeding the process for making hydrogen or synthesis gas
- C01B2203/1205—Composition of the feed
- C01B2203/1211—Organic compounds or organic mixtures used in the process for making hydrogen or synthesis gas
- C01B2203/1235—Hydrocarbons
- C01B2203/1247—Higher hydrocarbons
Definitions
- An improved reactor process includes providing at least one reactor tube, the reactor tube comprising an exterior and an interior, the interior comprising an inside surface, providing a heat source to the exterior of the at least one reactor tube, providing a reactant gas stream to the interior of the at least one reactor tube, placing at least one heat transfer structure in thermal contact with the inside surface of the at least one reactor tube, and transferring heat from the heat source to at least a portion of the reactant gas stream at least partially through the at least one heat transfer structure, thereby producing a product gas stream.
- the reactant gas stream may comprise methane and steam.
- FIG. 1 illustrates a heat transfer structure in thermal contact with the inside of a reactor tube, in accordance with one embodiment of the present invention.
- FIGS. 2 a - 2 h illustrate various configurations for a heat transfer structure, in accordance with one embodiment of the present invention.
- FIGS. 3 a - 3 c illustrate possible placements of the heat transfer structures within the length of the reactor tube, in accordance with one embodiment of the present invention.
- FIG. 4 illustrates the temperature profiles along the reactor centerline for with and without heat transfer structures, in accordance with one embodiment of the present invention.
- At least one metal structure 105 is installed inside a reactor tube 101 .
- This reactor tube may be a steam methane reformer (SMR) tube.
- SMR steam methane reformer
- Catalyst bed 106 and gases 107 inside reactor tube 101 are simultaneously heated by tube walls 108 and metal structures 105 .
- Energy is conducted to the interior and center of the packed catalyst bed by metal structures 105 directly.
- the average temperature of the catalyst bed at each cross section is higher comparing with the conventional design, and the temperature distribution is also more uniform.
- the shape, dimension, number of metal structures 105 and the installation locations are depending on the actual SMR reactor design and the SMR furnace operating conditions.
- the metal structures 105 are embedded in the catalyst bed 106 .
- a greater number of metal structures 105 may be installed in the initial section of the reactor tube to quickly heat up the catalyst bed.
- a lesser number of metal structures 105 can be installed in the downstream to keep the temperature distribution more uniform.
- Reactor tube 101 which comprises an exterior 102 and an interior 103 , with the interior 103 further comprising an inside surface 104 .
- the interior 103 may be filled with a catalyst 106 .
- a heat source Q is provided to the exterior 102 of the reactor tube 101 .
- Reactant gas stream 107 is provided to the interior of the reactor tube.
- At least one heat transfer structure 105 is placed in thermal contact with the inside surface 104 of the reactor tube 101 .
- Heat source Q transfers heat 110 through reactor tube 101 . Heat is then transferred 111 through heat transfer structure 105 . Heat is then transferred from heat transfer structure 105 to the interior 103 of reactor tube 101 . As the reactant gas stream 107 passes through the catalyst 106 , the heat transferred from heat transfer structure 105 (along with heat transferring 115 from the inside surface) product gas stream 114 is produced.
- Heat transfer structure 105 may have any shape which is achieves and retains thermal contact with the inside surface of the reactor tube, and which effectively transfers heat to the interior of the tube.
- One non-limiting example would be a spherical shape comprising two rings affixed to one another at right angles (as illustrated in FIG. 1 ).
- this spherical ring shape would be oriented such that one ring is in contact with the inside surface of the reactor tube along the entire circumference (as illustrated in FIGS. 2 a and 2 b ).
- heat transfer structure 105 may have a tripod shape (as illustrated in FIGS. 2 c and 2 d ). Such a shape may be planar when viewed radially ( FIG. 2 c ) or may have a “fin” that may be oriented upstream or downstream ( FIG. 2 d ), in order to better facilitate heat transfer.
- heat transfer structure 105 may have a cross-shape (as illustrated in FIGS. 2 e and 2 f ). Such a shape may be planar when viewed radially ( FIG. 2 e ) or may have a “fin” that may be oriented upstream or downstream ( FIG. 2 f ), in order to better facilitate heat transfer. Care should be taken in such designs as the heat transfer structure 105 will experience thermal growth E ir , in a radial direction and must be taken into account in order not to potentially damage the tube walls.
- heat transfer structure 105 may have a cross-shape or a tripod shape, or any suitable shape (illustrated for example by FIGS. 2 g and 2 h ).
- a fin of suitable shape illustrated here as a triangle may be utilized to allow thermal growth E ia , in an axial direction and have less potential to damage the tube walls.
- two or more heat transfer structures 105 may be positioned along the length of reactor tube 101 (as illustrated in FIG. 3 a )
- heat transfer structures 105 may be grouped into two or more sets.
- the first set S 1 which may be nearer the entrance of the tube, may have an average spacing of L 1
- the second set S 2 which is downstream of S 1 , may have an average spacing of L 2 .
- Average spacing L 1 may be closer together than average spacing L 2 . (as illustrated in FIG. 3 b ).
- two or more heat transfer structures 105 may be positioned only at the entrance end of reactor tube 101 (as illustrated in FIG. 3 c )
- the first simulation was for a conventional reactor tube.
- the second simulation was for a reactor tube with 9 metal structures, in accordance with one embodiment of the present invention, installed.
- the chemical reaction is not considered.
- the catalyst bed is represented by alumina beads and fluid is nitrogen.
- the reactor tube has a length of 13.1 meters (43 ft), OD of 136.5 mm (5.37 inch) and ID of 105.7 mm (4.16 inch) respectively.
- the metal structures are installed at different locations.
- the first 6 metal structures are spaced 0.91 m evenly along the tube starting at 1.37 m from the inlet.
- the following 3 metal structures are spaced 1.22 m evenly.
- FIG. 4 illustrates the temperature profiles along the reactor centerline for both cases.
- a portion of the compressed air from the compressed air combined cycle loop can be injected into the gas turbine and heated by the combustion of air and fuel to form a hot gas then expanded in the gas turbine to generate power.
Abstract
Description
- The production of gas products rich in hydrogen by reforming of hydrocarbons is well established in industry. Typically, long tubes are filled with catalyst, into which the hydrocarbon and steam are introduced. The obtained reformate, known as “synthesis gas”, contains primarily hydrogen and carbon monoxide. The overall reaction is endothermic, and consequently a source of heat is required to externally heat the reaction tubes in which the input mixture of methane and steam is passed. It has been found that by directing heat from the tube wall to the interior of the catalyst, throughput may be improved.
- An improved reactor process is provided. This process includes providing at least one reactor tube, the reactor tube comprising an exterior and an interior, the interior comprising an inside surface, providing a heat source to the exterior of the at least one reactor tube, providing a reactant gas stream to the interior of the at least one reactor tube, placing at least one heat transfer structure in thermal contact with the inside surface of the at least one reactor tube, and transferring heat from the heat source to at least a portion of the reactant gas stream at least partially through the at least one heat transfer structure, thereby producing a product gas stream. There may be a catalyst on the interior of the at least one reactor tube. The reactant gas stream may comprise methane and steam.
-
FIG. 1 illustrates a heat transfer structure in thermal contact with the inside of a reactor tube, in accordance with one embodiment of the present invention. -
FIGS. 2 a-2 h illustrate various configurations for a heat transfer structure, in accordance with one embodiment of the present invention. -
FIGS. 3 a-3 c illustrate possible placements of the heat transfer structures within the length of the reactor tube, in accordance with one embodiment of the present invention. -
FIG. 4 illustrates the temperature profiles along the reactor centerline for with and without heat transfer structures, in accordance with one embodiment of the present invention. - Illustrative embodiments of the invention are described below. While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
- It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
- Turning to
FIG. 1 , in one aspect of the current invention, at least onemetal structure 105 is installed inside areactor tube 101. This reactor tube may be a steam methane reformer (SMR) tube.Catalyst bed 106 andgases 107 insidereactor tube 101 are simultaneously heated bytube walls 108 andmetal structures 105. Energy is conducted to the interior and center of the packed catalyst bed bymetal structures 105 directly. The average temperature of the catalyst bed at each cross section is higher comparing with the conventional design, and the temperature distribution is also more uniform. - The shape, dimension, number of
metal structures 105 and the installation locations are depending on the actual SMR reactor design and the SMR furnace operating conditions. Themetal structures 105 are embedded in thecatalyst bed 106. A greater number ofmetal structures 105 may be installed in the initial section of the reactor tube to quickly heat up the catalyst bed. A lesser number ofmetal structures 105 can be installed in the downstream to keep the temperature distribution more uniform. - Turning now to
FIGS. 1 , 2, and 3, an improved reactor process is illustrated. Note, in the interest of clarity, the same element numbers are consistently maintained throughout these figures.Reactor tube 101, which comprises anexterior 102 and aninterior 103, with theinterior 103 further comprising aninside surface 104. Theinterior 103 may be filled with acatalyst 106. A heat source Q is provided to theexterior 102 of thereactor tube 101.Reactant gas stream 107 is provided to the interior of the reactor tube. At least oneheat transfer structure 105 is placed in thermal contact with theinside surface 104 of thereactor tube 101. - Heat source Q transfers
heat 110 throughreactor tube 101. Heat is then transferred 111 throughheat transfer structure 105. Heat is then transferred fromheat transfer structure 105 to theinterior 103 ofreactor tube 101. As thereactant gas stream 107 passes through thecatalyst 106, the heat transferred from heat transfer structure 105 (along with heat transferring 115 from the inside surface)product gas stream 114 is produced. -
Heat transfer structure 105 may have any shape which is achieves and retains thermal contact with the inside surface of the reactor tube, and which effectively transfers heat to the interior of the tube. One non-limiting example would be a spherical shape comprising two rings affixed to one another at right angles (as illustrated inFIG. 1 ). In a preferred embodiment, this spherical ring shape would be oriented such that one ring is in contact with the inside surface of the reactor tube along the entire circumference (as illustrated inFIGS. 2 a and 2 b). - In another embodiment,
heat transfer structure 105 may have a tripod shape (as illustrated inFIGS. 2 c and 2 d). Such a shape may be planar when viewed radially (FIG. 2 c) or may have a “fin” that may be oriented upstream or downstream (FIG. 2 d), in order to better facilitate heat transfer. - In another embodiment,
heat transfer structure 105 may have a cross-shape (as illustrated inFIGS. 2 e and 2 f). Such a shape may be planar when viewed radially (FIG. 2 e) or may have a “fin” that may be oriented upstream or downstream (FIG. 2 f), in order to better facilitate heat transfer. Care should be taken in such designs as theheat transfer structure 105 will experience thermal growth Eir, in a radial direction and must be taken into account in order not to potentially damage the tube walls. - In another embodiment,
heat transfer structure 105 may have a cross-shape or a tripod shape, or any suitable shape (illustrated for example byFIGS. 2 g and 2 h). In this embodiment, a fin of suitable shape (illustrated here as a triangle) may be utilized to allow thermal growth Eia, in an axial direction and have less potential to damage the tube walls. - In one embodiment, two or more
heat transfer structures 105 may be positioned along the length of reactor tube 101 (as illustrated inFIG. 3 a) - The entrance end of the tube, wherein
reactant gas stream 107 enters, will have a higher average tube wall temperature then the exit end of the tube, wherein theproduct gas stream 114 exits. In one embodiment,heat transfer structures 105 may be grouped into two or more sets. The first set S1, which may be nearer the entrance of the tube, may have an average spacing of L1, and the second set S2, which is downstream of S1, may have an average spacing of L2. Average spacing L1 may be closer together than average spacing L2. (as illustrated inFIG. 3 b). - In one embodiment, two or more
heat transfer structures 105 may be positioned only at the entrance end of reactor tube 101 (as illustrated inFIG. 3 c) - Two computational fluid dynamics simulations were conducted. The first simulation was for a conventional reactor tube. The second simulation was for a reactor tube with 9 metal structures, in accordance with one embodiment of the present invention, installed. The chemical reaction is not considered. The catalyst bed is represented by alumina beads and fluid is nitrogen. The reactor tube has a length of 13.1 meters (43 ft), OD of 136.5 mm (5.37 inch) and ID of 105.7 mm (4.16 inch) respectively. The metal structures are installed at different locations. The first 6 metal structures are spaced 0.91 m evenly along the tube starting at 1.37 m from the inlet. The following 3 metal structures are spaced 1.22 m evenly.
FIG. 4 illustrates the temperature profiles along the reactor centerline for both cases. - It should be noted that while the invention has been described in several different embodiment, it is obvious that some additional embodiments can be developed or added by the persons skilled in the art or familiar with the technology to further improve the invention without departing from the scope of this disclosure. For example, a portion of the compressed air from the compressed air combined cycle loop can be injected into the gas turbine and heated by the combustion of air and fuel to form a hot gas then expanded in the gas turbine to generate power.
Claims (19)
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US13/327,924 US20130153188A1 (en) | 2011-12-16 | 2011-12-16 | Advanced smr reactor design featuring high thermal efficiency |
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US13/327,924 US20130153188A1 (en) | 2011-12-16 | 2011-12-16 | Advanced smr reactor design featuring high thermal efficiency |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2016062932A1 (en) | 2014-10-21 | 2016-04-28 | L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude | Reforming furnace comprising reforming tubes with fins |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4400309A (en) * | 1972-06-30 | 1983-08-23 | Foster Wheeler Energy Corporation | Process for activating a steam reforming catalyst and the catalyst produced by the process |
US20030066638A1 (en) * | 2001-08-13 | 2003-04-10 | Yuzhi Qu | Devices using a medium having a high heat transfer rate |
US20080159465A1 (en) * | 2006-11-13 | 2008-07-03 | Kabushiki Kaisha Toshiba | Fast reactor |
US20100312021A1 (en) * | 2008-02-25 | 2010-12-09 | Max Thorhauge | Reactor for the preparation of methanol |
-
2011
- 2011-12-16 US US13/327,924 patent/US20130153188A1/en not_active Abandoned
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4400309A (en) * | 1972-06-30 | 1983-08-23 | Foster Wheeler Energy Corporation | Process for activating a steam reforming catalyst and the catalyst produced by the process |
US20030066638A1 (en) * | 2001-08-13 | 2003-04-10 | Yuzhi Qu | Devices using a medium having a high heat transfer rate |
US20080159465A1 (en) * | 2006-11-13 | 2008-07-03 | Kabushiki Kaisha Toshiba | Fast reactor |
US20100312021A1 (en) * | 2008-02-25 | 2010-12-09 | Max Thorhauge | Reactor for the preparation of methanol |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2016062932A1 (en) | 2014-10-21 | 2016-04-28 | L'air Liquide, Societe Anonyme Pour L'etude Et L'exploitation Des Procedes Georges Claude | Reforming furnace comprising reforming tubes with fins |
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