WO2010056459A2

WO2010056459A2 - Vertical shaft reactors with injection systems

Info

Publication number: WO2010056459A2
Application number: PCT/US2009/060800
Authority: WO
Inventors: Jens Wiik Jensen; Eric Dickman
Original assignee: Uni-Control, Llc
Priority date: 2008-11-12
Filing date: 2009-10-15
Publication date: 2010-05-20
Also published as: WO2010056459A3

Abstract

Embodiments disclosed herein present a system, comprising a vertical shaft reactor and at least one injection nozzle in fluid communication with at least one inlet that is connected to at least one feed stream. The at least one injection nozzle is configured to be at positions in the reactor to introduce at least one substance to achieve desirable effects related to the reaction. Embodiments disclosed herein also describe a method of utilizing an injection system in a vertical shaft reactor comprising (1) installing at least one injection nozzle; and (2) introducing at least one substance to at least one nozzle via at least one feed stream.

Description

VERTICAL SHAFT REACTORS WITH INJECTION SYSTEMS

FIELD OF THE INVENTION

[0001] This invention relates to vertical shaft reactors; and particularly to vertical shaft reactors with injection systems.

BACKGROUND

[0002] Vertical shaft reactors are useful in such applications as waste water treatment, biomass conversion, and biological nitrification. For certain processes and reactions to take place, it is desirable to control the concentrations of substances along the progression of the reaction. For certain other processes, it is desirable to terminate the reaction or to introduce a new reaction. For yet other processes, it is desirable to initiate or start the reaction in the reactor by introducing substances in their dispersed forms. One method is to install an injection system with injection nozzles at different locations in a reactor to add one or more fresh substances, or to increase or decrease the concentration of one or more substances.

SUMMARY

[0003] Herein disclosed is a system, comprising a vertical shaft reactor and at least one injection nozzle in fluid communication with at least one inlet that is connected to at least one feed stream. In some embodiments, the system further comprises at least one control system that is configured to regulate at least one of the following parameters (1) the timing of the injection of a fluid, including the initiation, the termination, and the frequency of injection; (2) the flow rate of injected fluid; (3) the pressure of injected fluid; and (4) the amount of injected fluid. In some embodiments, the system further comprises at least one pump that is configured to be in fluid communication with the injection nozzle and the feed stream. In some embodiments, the system further comprises at least one thermometer that is configured to measure the temperature of the feed stream. In some embodiments, the system further comprises at least one heat exchange system to vary the temperature of the feed stream. [0004] In some embodiments, a first nozzle is positioned in the middle of the reactor and a second nozzle is positioned differently from the first nozzle in altitude. In some embodiments, a first nozzle is positioned in the middle of the reactor and a second nozzle is positioned differently from the first in the radial direction. In some embodiments, a first nozzle is positioned in the middle of the reactor and a second nozzle is positioned differently from the first in the circumferential direction. In some embodiments, a nozzle is positioned in the center of the reactor, in altitude, in the radial direction, and in the circumferential direction. In some embodiments, a first nozzle is positioned on the wall of the reactor and a second nozzle is positioned on the wall of the reactor at a different altitude. In some embodiments, a first nozzle is positioned on the wall of the reactor and a second nozzle is positioned differently on the wall of the reactor in the circumferential direction. [0005] Herein also disclosed is a method of introducing at least one substance into a vertical shaft reactor. The method comprises (1) obtaining one of the systems described above; and (2) introducing at least one substance via at least one feed stream to at least one nozzle. In some embodiments, the substance introduced is in a form of a fluid, comprising a gas, a gas with dispersed liquids, a gas with dispersed solids, a gas with dispersed liquids and solids, a liquid, a liquid with dispersed gases, a liquid with dispersed solids, a liquid with dispersed gases and solids, a gas mixture, a liquid mixture, a liquid with dispersed liquids. In some embodiments, the substance is in a form of a fluid, comprising a solvent, a solution, and an emulsion.

[0006] In some embodiments, different compositions or concentrations of a substance are introduced to different nozzles. In some embodiments, different substances are introduced to different nozzles. In some embodiments, different substances or different compositions or concentrations of a substance are introduced via the at least one nozzle at different time points of a reaction, including before the initiation of a reaction, during a reaction, and at the end of a reaction.

[0007] In some embodiments, the at least one feed stream at different temperatures is introduced to different nozzles. In some embodiments, introducing a substance precedes the initiation of a reaction. In some embodiments, introducing a substance takes place in the middle of a reaction. In some embodiments, introducing a substance follows the end of a reaction in the operational sense.

[0008] These and other embodiments of the present invention, and various features and potential advantages will be apparent with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure Ia is a schematic drawing of a vertical shaft reactor with injection nozzles installed in the middle of the reactor, in accordance with an embodiment of the invention.

[0010] Figure Ib is a schematic drawing of a vertical shaft reactor with injection nozzles installed on the wall of the reactor, in accordance with an embodiment of the invention.

[0011] Figure 2a is a schematic drawing of a vertical shaft reactor with a partition in the middle and injection nozzles installed on the wall of the reactor, in accordance with an embodiment of the invention.

[0012] Figure 2b is a schematic top-down view of a vertical shaft reactor with a partition in the middle and injection nozzles installed on the wall of the reactor, in accordance with an embodiment of the invention.

[0013] Figure 3a is a schematic drawing of a vertical shaft reactor with a chamber in the middle and injection nozzles installed on the wall of the reactor, in accordance with an embodiment of the invention.

[0014] Figure 3b is a schematic top-down view of a vertical shaft reactor with a chamber in the middle and injection nozzles installed on the wall of the reactor, in accordance with an embodiment of the invention.

[0015] Figure 4a is a schematic drawing of a vertical shaft reactor with a chamber in the middle and injection nozzles installed in the middle of the inner chamber and on the wall of the reactor, in accordance with an embodiment of the invention.

[0016] Figure 4b is a schematic top-down view of a vertical shaft reactor with a chamber in the middle and injection nozzles installed in the middle of the inner chamber and on the wall of the reactor, in accordance with an embodiment of the invention.

[0017] Figure 5a is a schematic drawing of a vertical shaft reactor with a partition in the middle and injection nozzles installed on the wall of the reactor that are connected to a control system, in accordance with an embodiment of the invention.

[0018] Figure 5b is a schematic drawing of a vertical shaft reactor with a chamber in the middle and injection nozzles installed on the wall of the reactor that are connected to a control system, in accordance with an embodiment of the invention. NOTATION AND NOMENCLATURE

[0019] Certain terms are used throughout the following description and claims to refer to particular system components. This document does not intend to distinguish between components that differ in name but not function.

[0020] Vertical shaft reactors disclosed herein include all such reactors for all purposes and applications, not limited by their size, shape, function, method of use, or material of make. Embodiments and related figures used herein are only exemplary and are not to limit the scope of the invention as set forth in the appended claims.

[0021] Injection nozzles disclosed herein include all injection heads with the necessary components for all purposes and applications, not limited by their design, size, shape, function, method of use, or material of make. Embodiments and related figures used herein are only exemplary and are not to limit the scope of the invention as set forth in the appended claims.

[0022] The term 'radial' is used hereinafter to describe the positional relationship between a said object and the center of a plane that is perpendicular or parallel to a reference plane, e.g., the ground, a surface of the reactor (the top, the bottom, the sides). The term 'circumferential' is used hereinafter to describe positions along the circumference of a plane that is perpendicular or parallel to a reference plane, e.g., the ground, a surface of the reactor (the top, the bottom, the sides). The term 'altitude' is used hereinafter to describe the height of a said object in relation to a reference plane, e.g., the ground, a surface of the reactor (the top, the bottom, the sides).

[0023] The end of a reaction is defined hereinafter to be in the operational sense. Rarely any reaction is 100% completed in the desired direction chemically or biochemically, but in the operational sense, a reaction ends when a reaction has proceeded to a desired extent or a preset reaction time has been reached.

DETAILED DESCRIPTION

Vertical Shaft Reactors with Injection Nozzles

[0024] In one embodiment (Figure Ia), an injection system comprising one or more injection nozzles 10 and one or more feed streams 15 is installed in the middle of the vertical shaft reactor 100. The nozzles and the feed streams are in fluid communication with one another via one or more inlets leading to the nozzles. Depending on the progression of the reaction and substances needed, the position or positions of nozzle installation in the middle of the reactor may be any in altitude and in the radial direction with respect to the top or bottom of the reactor. The installed nozzles may be any as known to one skilled in the art to achieve desired effects of introducing substances.

[0025] For example, injections nozzles are installed for reaction CO + H₂O <→ CO₂ + H₂ to take place in a vertical shaft reactor. To drive the equilibrium of this reaction to the right hand side (RHS) for hydrogen production, feed stream made of CO or H₂O or their combination is sent to the injection nozzles. At the same time, the product gases (CO₂ and H₂) may be extracted from the reactor. In other examples, fresh reactants may be added to increase the concentration of the reactants in order to increase the rate of the reaction and/or to shift the reaction equilibrium. In some other reactions, a solvent may be added to dilute the reaction mixture to control the extent and/or rate of reaction. In certain other reactions, neutralizers may be added to eliminate or to reduce one of the substances in the reaction mixture to shift the reaction equilibrium to one side of the reaction. In some further examples, a new reaction may be added by introducing a new substance via one or more installed injection nozzles to react with one or more of the substances in the reaction mixture. In yet other examples, reaction may be quenched or terminated by introducing a suitable substance via one or more installed injection nozzles into the reaction mixture.

[0026] In some cases, one or more pumps 20 are included, which are configured to be in fluid communication with feed streams 15 and one or more or all of the stalled nozzles 10. Pump 20 is configured for either continuous or semi-continuous operation, and may be any suitable pumping device. The purpose of utilizing the pumps is to ensure suitable amounts of fluids are supplied to the nozzles at suitable rates. In some embodiments, one or more thermometers are included, which are configured to measure the temperature of feed streams 15 before they reach the nozzles and get ejected. In further embodiments, at least one heat exchange system is included to raise or to decrease the temperature of feed streams 15 before they reach the nozzles.

[0027] In another embodiment (Figure Ib), an injection system comprising one or more injection nozzles 10 and one or more feed streams 15 is installed on the wall of the vertical shaft reactor 100. The nozzles and the feed streams are in fluid communication with one another via one or more inlets leading to the nozzles. Depending on the progression of the reaction and substances needed, the position or positions of nozzle installation on the wall of the reactor may be any in altitude and in the circumferential direction with respect to the top or bottom of the reactor. The installed nozzles may be any as known to one skilled in the art to achieve desired effects of introducing substances.

[0028] In some cases, one or more pumps 20 are included, which are configured to be in fluid communication with feed streams 15 and one or more or all of the stalled nozzles 10. Pump 20 is configured for either continuous or semi-continuous operation, and may be any suitable pumping device. The purpose of utilizing the pumps is to ensure suitable amounts of fluids are supplied to the nozzles at suitable rates. In some embodiments, one or more thermometers are included, which are configured to measure the temperature of feed streams 15 before they reach the nozzles and get ejected. In further embodiments, at least one heat exchange system is included to raise or to decrease the temperature of feed streams 15 before they reach the nozzles.

[0029] In a further embodiment (Figure 2a), an injection system comprising one or more injection nozzles 10 and one or more feed streams 15 and 45 is installed on the wall of the vertical shaft reactor 100. The nozzles and the feed streams are in fluid communication with one another via one or more inlets leading to the nozzles. The vertical shaft reactor 100 comprises a partition 30 in the middle, which is further illustrated in the top-down view in Figure 2b. In some embodiments, the partition extends the entire length of the reactor. In other embodiments, the partition extends a portion of the reactor. The position of partition 30 may be any in altitude and in the radial direction with respect to the top or bottom of the reactor. In certain embodiments, partition 30 is inclined with respect to the top or bottom of the reactor. Depending on the progression of the reaction and substances needed, the position or positions of nozzle installation on the wall of the reactor may be any in altitude and in the circumferential direction with respect to the top or bottom of the reactor. The installed nozzles may be any as known to one skilled in the art to achieve desired effects of introducing substances.

[0030] In some cases, one or more pumps 20 are included, which are configured to be in fluid communication with feed streams 15 and 45 and one or more or all of the stalled nozzles 10. Pump 20 is configured for either continuous or semi-continuous operation, and may be any suitable pumping device. The purpose of utilizing the pumps is to ensure suitable amounts of fluids are supplied to the nozzles at suitable rates. In some embodiments, one or more thermometers are included, which are configured to measure the temperature of feed streams 15 and/or 45 before they reach the nozzles and get ejected. In further embodiments, at least one heat exchange system is included to raise or to decrease the temperature of feed streams 15 and/or 45 before they reach the nozzles. [0031] In an embodiment (Figure 3a), a injection system comprising one or more injection nozzles 10 and one or more feed streams 15 is installed on the wall of the vertical shaft reactor 100. The nozzles and the feed streams are in fluid communication with one another via one or more inlets leading to the nozzles. The vertical shaft reactor 100 comprises an inner chamber 40 in the middle, which is further illustrated in the top-down view in Figure 3b. In some embodiments, the inner chamber extends the entire length of the reactor. In other embodiments, the inner chamber extends a portion of the reactor. The position of inner chamber 40 may be any in altitude and in the radial direction with respect to the top or bottom of the reactor. Depending on the progression of the reaction and substances needed, the position or positions of nozzle installation on the wall of the reactor may be any in altitude and in the circumferential direction with respect to the top or bottom of the reactor. The installed nozzles may be any as known to one skilled in the art to achieve desired effects of introducing substances.

[0032] In some cases, one or more pumps 20 are included, which are configured to be in fluid communication with feed streams 15 and one or more or all of the stalled nozzles 10. Pump 20 is configured for either continuous or semi-continuous operation, and may be any suitable pumping device. The purpose of utilizing the pumps is to ensure suitable amounts of fluids are supplied to the nozzles at suitable rates. In some embodiments, one or more thermometers are included, which are configured to measure the temperature of feed streams 15 before they reach the nozzles and get ejected. In further embodiments, at least one heat exchange system is included to raise or to decrease the temperature of feed streams 15 before they reach the nozzles.

[0033] In another embodiment (Figure 4a), vertical shaft reactor 100 comprises an inner chamber 40 in the middle, which is further illustrated in the top-down view in Figure 4b. A injection system comprising one or more injection nozzles 10 and one or more feed streams 15 and 45 is installed in the middle of the inner chamber 40 and on the wall of the vertical shaft reactor 100. The nozzles and the feed streams are in fluid communication with one another via one or more inlets leading to the nozzles. In some embodiments, the inner chamber extends the entire length of the reactor. In other embodiments, the inner chamber extends a portion of the reactor. The position of inner chamber 40 may be any in altitude and in the radial direction with respect to the top or bottom of the reactor.

[0034] Depending on the progression of the reaction and substances needed; the position or positions of nozzle installation in the middle of the inner chamber may be any in altitude and in the radial direction with respect to the top or bottom of the reactor; the position or positions of nozzle installation on the wall of the reactor may be any in altitude and in the circumferential direction with respect to the top or bottom of the reactor. The installed nozzles may be any as known to one skilled in the art to achieve desired effects of introducing substances.

[0035] In some cases, one or more pumps 20 are included, which are configured to be in fluid communication with feed streams 15 and 45 and one or more or all of the stalled nozzles 10. Pump 20 is configured for either continuous or semi-continuous operation, and may be any suitable pumping device. The purpose of utilizing the pumps is to ensure suitable amounts of fluids are supplied to the nozzles at suitable rates. In some embodiments, one or more thermometers are included, which are configured to measure the temperature of feed streams 15 and/or 45 before they reach the nozzles and get ejected. In further embodiments, at least one heat exchange system is included to raise or to decrease the temperature of feed streams 15 and/or 45 before they reach the nozzles.

[0036] In certain embodiments (Figure 5a and Figure 5b), the injection nozzles are connected to a control system 70. The control system may be any suitable system known to one skilled in the art, including automated control system, manual control system, semi-automated control system, programmed control system. The control system regulates at least one of the following factors: (1) the timing of the injection of fluids, including the initiation, the termination, and the frequency of injection; (2) the flow rate of injected fluids; (3) the pressure of injected fluids; and (4) the amounts of injected fluids. In certain further embodiments, said control system correlates the regulated injection of different nozzles to achieve specific objectives. Said control system may be further directed by a feedback signal that is based on an action or a phenomenon that is mechanical, electrical, chemical, physical, physicochemical, photophysical, photochemical, biological or biochemical.

Operation of the Injection System

[0037] The feed streams may be any fluids or fluid mixtures that are needed to achieve the desired effects. For example, the feed stream is a fluid, comprising a gas, a gas with dispersed liquids, a gas with dispersed solids, a gas with dispersed liquids and solids, a liquid, a liquid with dispersed gases, a liquid with dispersed solids, a liquid with dispersed gases and solids. The feed stream may also be a fluid mixture, including a gas mixture, a liquid mixture, and a liquid with dispersed liquids. Furthermore, the feed stream may be a fluid, comprising a solvent, a solution, and an emulsion. [0038] In some embodiments, fresh reactants are added to increase the concentration of the reactants in order to increase the rate of the reaction and/or to shift the reaction equilibrium. In other embodiments, a solvent is added to dilute the reaction mixture to control the extent and/or rate of reaction. In some other embodiments, neutralizers are added to eliminate or to reduce one of the substances in the reaction mixture to shift the reaction equilibrium to one side of the reaction. In some further embodiments, a new reaction is initiated by introducing a new substance to react with one or more of the substances in the reaction mixture. In yet other embodiments, a reaction is quenched or terminated by introducing a suitable substance into the reaction mixture.

[0039] The feed stream composition may be any that is suitable for the task at hand as known to one skilled, which composition may also be changed at different times during the operation of the reactor. The compositions of feed streams 15 and 45 may be different, depending on the need of substances to be introduced into different regions of the reactor. In some embodiments, feed streams are heated or cooled prior to being sent to the injection nozzles to achieve the most ideal results. Substances utilized as feed streams may be acquired by any means as known to one skilled in the art, either self-made or obtained through the purchase of commercially available substances. Substances are supplied to the feed streams utilizing at least one vessel with necessary components, such as tubes, pipes, and pumps. [0040] In some embodiments, substances are introduced via the injection nozzles in the middle of a reaction to achieve effects such as shifting the reaction equilibrium, increasing or decreasing the reaction rate. In some other embodiments, substances are introduced via the injection nozzles at the end of a reaction (in the operational sense) to achieve effects such as initiating a new reaction, quenching or terminating a reaction. In yet other embodiments, substances are introduced via the injection nozzles at the beginning of a reaction to achieve effects such as increasing the reaction rate by mixing reactants in their dispersed forms. [0041] In embodiments, injection nozzles may be used in a fashion so as to create or maintain a concentration gradient of at least one substance in the reaction mixture by injecting feed streams that contain different substances or different concentrations of a substance via different nozzles. For example, in some bio-reactors it is desirable to provide optimal concentrations of a growth substrate for microbes according to the local concentrations of the microbes, which reduces potential toxicity and increases reaction efficiency. In certain embodiments, injection nozzles may be used in a fashion so as to create or maintain a temperature gradient in the reactor by injecting feed streams that are kept at different temperatures via different nozzles. [0042] The selection of an injection nozzle (e.g., size, type, and method of use) depends on the task at hand. For example, to increase the concentration of a substance in a uniform manner in a reactor or a reactor zone, the injection nozzle is chosen so that the volume impacted by the spray is substantial compared to the volume of said reactor or reactor zone. If a concentration gradient or a temperature gradient is to be created, the injection nozzle is chosen so that the volume impacted by the spray is effectively small compared to the volume of a reactor or a reactor zone in order to achieve localized concentration or temperature changes.

[0043] In some other embodiments, fluids for other purposes may be introduced via the injection system. For example, steam may be introduced into the reactor via the injection nozzles to sterilize the reactor prior to the start of the reaction. Another example is to spray a cleaning solution via the injection nozzles to clean one or more surfaces of the reactor. The injection system is therefore a multi-functional system for a vertical shaft reactor. [0044] The foregoing has outlined the features and technical advantages of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.

[0045] In the following claims, the terms "including" and "comprising" are used in an open- ended fashion, and thus should be interpreted to mean "including, but not limited to ...".

Claims

CLAIMSWe claim:

1. A system comprising a vertical shaft reactor and at least one injection nozzle in fluid communication with at least one inlet that is connected to at least one feed stream.

2. The system of claim 1 further comprising at least one control system that is configured to regulate at least one of the following parameters a. the timing of the injection of a fluid, including the initiation, the termination, and the frequency of injection; b. the flow rate of injected fluid; c. the pressure of injected fluid; and d. the amount of injected fluid.

3. The system of claim 1 further comprising at least one pump that is configured to be in fluid communication with the injection nozzle and the feed stream.

4. The system of claim 1 further comprising at least one thermometer that is configured to measure the temperature of the feed stream.

5. The system of claim 1 further comprising at least one heat exchange system to vary the temperature of the feed stream.

6. The system of claim 1 wherein a first nozzle is positioned in the middle of the reactor and a second nozzle is positioned differently from the first nozzle in altitude.

7. The system of claim 1 wherein a first nozzle is positioned in the middle of the reactor and a second nozzle is positioned differently from the first in the radial direction.

8. The system of claim 1 wherein a first nozzle is positioned in the middle of the reactor and a second nozzle is positioned differently from the first in the circumferential direction.

9. The system of claim 1 wherein a nozzle is positioned in the center of the reactor, in altitude, in the radial direction, and in the circumferential direction.

10. The system of claim 1 wherein a first nozzle is positioned on the wall of the reactor and a second nozzle is positioned on the wall of the reactor at a different altitude.

11. The system of claim 1 wherein a first nozzle is positioned on the wall of the reactor and a second nozzle is positioned differently on the wall of the reactor in the circumferential direction.

12. A method of introducing at least one substance into a vertical shaft reactor comprising a. obtaining one of the systems disclosed in claims 1-11; and b. introducing at least one substance via at least one feed stream to at least one nozzle.

13. The method of claim 12 wherein said at least one substance is in a form of a fluid, comprising a gas, a gas with dispersed liquids, a gas with dispersed solids, a gas with dispersed liquids and solids, a liquid, a liquid with dispersed gases, a liquid with dispersed solids, a liquid with dispersed gases and solids, a gas mixture, a liquid mixture, a liquid with dispersed liquids.

14. The method of claim 12 wherein said at least one substance is in a form of a fluid, comprising a solvent, a solution, and an emulsion.

15. The method of claim 12 wherein said at least one substance of different compositions or concentrations are introduced to different nozzles.

16. The method of claim 12 wherein said at least one substance comprises different substances and different substances are introduced to different nozzles.

17. The method of claim 12 wherein different substances or different compositions or concentrations of a substance are introduced via the at least one nozzle at different time points of a reaction, including before the initiation of a reaction, during a reaction, and at the end of a reaction.

18. The method of claim 12 wherein said at least one feed stream at different temperatures is introduced to different nozzles.

19. The method of claim 12 wherein introducing said at least one substance precedes the initiation of a reaction.

20. The method of claim 12 wherein introducing said at least one substance takes place in the middle of a reaction.

21. The method of claim 12 wherein introducing said at least one substance follows the end of a reaction in the operational sense.