Classifications

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  • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
  • B01J19/24—Stationary reactors without moving elements inside
  • B01J19/2415—Tubular reactors
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B01J12/00—Chemical processes in general for reacting gaseous media with gaseous media; Apparatus specially adapted therefor
  • B01J12/007—Chemical processes in general for reacting gaseous media with gaseous media; Apparatus specially adapted therefor in the presence of catalytically active bodies, e.g. porous plates
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  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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  • B01J19/0006—Controlling or regulating processes
  • B01J19/0013—Controlling the temperature of the process
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  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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  • B01J19/243—Tubular reactors spirally, concentrically or zigzag wound
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  • B01J19/30—Loose or shaped packing elements, e.g. Raschig rings or Berl saddles, for pouring into the apparatus for mass or heat transfer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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  • B01J2219/00076—Controlling the temperature by indirect heating or cooling employing heat exchange fluids with heat exchange elements inside the reactor
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  • B01J2219/194—Details relating to the geometry of the reactor round
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  • B01J2219/2403—Geometry of the channels
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  • B01J2219/2451—Geometry of the reactor
  • B01J2219/2456—Geometry of the plates
  • B01J2219/2459—Corrugated plates
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B01J2219/2461—Heat exchange aspects
  • B01J2219/2462—Heat exchange aspects the reactants being in indirect heat exchange with a non reacting heat exchange medium
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B01J2219/2461—Heat exchange aspects
  • B01J2219/2467—Additional heat exchange means, e.g. electric resistance heaters, coils
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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  • B01J2219/2476—Construction materials
  • B01J2219/2477—Construction materials of the catalysts
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• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B01J2219/32475—Composition or microstructure of the elements comprising catalytically active material involving heat exchange

Definitions

• the present invention relates to an expandable centre arrangement for a reactor, to a reactor and to a method of installing an expandable centre arrangement in a reactor.
• the present invention relates to an expandable centre arrangement for a stackable structured reactor, to a stackable structured reactor and to a method of installing such an arrangement in such a reactor.
• Reactor components for carrying out catalytic reactions can generally contact reactor tubes exposed to a heat source, for example a furnace , to support reactions.
• a heat source for example a furnace
• other types of reactions such as exothermic reactions
• the reactor tubes can be loaded with various arrangements of catalyst-coated components, such as foil-supported or structured catalysts in the form of fans, fins, coils, foams, or monoliths.
• the reactor cata1yst-coated components can be expandable, such as those formed from foil, for example, a fan .
• WO2013151889 describes an expandable centre arrangement for use in a tubular reactor, such as a reformer, for enhancing heat transfer and reactor efficiency.
• the expandable centre arrangement can include a cone being expandable in the radial direction and an expansion weight, for promoting expansion of the cone.
• the cone and expansion weight can be slidable arranged on a centre support.
• Expansion of the cones in the radial direction forces reactor catalyst-coated components radially outward to an outer tube that houses the reactor catalyst-coated components and expandable centre arrangement. Expansion of reactor catalyst-coated components towards the outer tube promotes heat transfer for carrying out catalytic reactions .
• Preferred embodiments of the present invention seek to overcome one or more of the above disadvantages of the prior art. In particular, preferred embodiments of the present invention seek to provide improved expandable centre
• an expandable centre arrangement for a reactor comprising: an expansion tube; a centre support inside the expansion tube and three or more spring elements; the spring elements being fastened to the centre support and arcing out to the expansion tube.
• Such an arrangement may provide an expandable centre that provides an expansive force to the structured catalyst-coated components of the reactor, while not requiring a large number of separate moving parts, The arrangement is thus
• the spring elements are preferably resilient so as to bias the expansion tube outwardly away from the centre support.
• the expansion tube may be formed from tail ends of the spring elements wrapping around and overlapping each other.
• the spring elements preferably spiral around and overlap each other.
• the spring elements preferably have head ends fastened to the centre support and tail ends overlapping to form the expansion tube.
• each of the tail ends extends around at. least one full circumference of the expansion tube.
• the expansion tube may be separate to the spring elements and the spring elements may press outwardly against the expansion tube.
• the spring elements may press outwardly from the centre support against the inside of the expansion tube .
• Such a system may be advantageous, for example, when different material properties are desirable for the spring elements and the expansion tube.
• the spring elements are sheet-like elements aligned with the axial direction of the centre support and the expansion tube.
• the centre support and expansion tube are preferably substantially straight with the centre support (for example, a tube or rod) aligned
• the spring elements preferably comprise sheets of a resilient material, such as metal, and are preferably fastened along one edge to the centre support so that first opposite edges of the sheets are aligned with the centre support and the longitudinal axis of the expansion tube and second opposite edges of the sheets arc out from the centre support to the expansion tube.
• a resilient material such as metal
• the expansion tube resists compression. That resistance may be as a result of frictional forces between layers.
• the expansion tube comprises at least one sheet wrapped around multiple times to form the circumference of the expansion tube. hat may produce an overlapping area that provides a high degree of resistance to compression of the tube.
• the at least one sheet may be the tails of the spring elements. The multiple wraps may be provided by each tail being wrapped around at least one circumference of the expan sion tube.
• a reactor comprising: an outer tube; an expansion tube inside the outer tube; an expandable catalyst support occupying an annular space between the expansion tube and the outer tube; and three or more curved resilient spring elements arranged within the expansion tube so as to bias the expansion tube toward the outer tube.
• the spring elements are mounted on a centre support.
• the centre support may be used to provide rigidity to the structure and may be used to handle the structure during installation and removal.
• the expansion tube is formed from tail ends of the spring elements wrapping around and overlapping each other. It may be that the expansion tube is separate to the spring elements.
• the spring elements are sheet-like elements aligned with the axial direction of the outer tube and the expan sion tube.
• the expansion tube comprises at least one sheet “wrapped around multiple times to form, the circumference of the expansion tube.
• Preferable reactors of the invention can include multiple catalyst support components arranged around or stacked on a centre support, such as a central rod or mandrel, pipe, post or the like, in order to form a monolith of general annular cross section as viewed in the direction of flow of fluid through the reactor.
• the monolith or stacked catalyst supports can occupy all or a portion of the annular space between two concentrically arranged tubes, such as an outer tube and an inner tube.
• the inner tube may be referred to as an expansion tube.
• various modifications and embodiments of the reactors and associated reactor components can be used in connection with expandable centre arrangements to promote neat transfer and reactor efficiency .
• Materials of construction for all reactor components or parts thereof can include any suitable material as known in the art, for example, metal, non-ferrous metal, metal foil, steel, stainless steel, alloys, foils, non-metals such as plastics or glass, ceramic, or combinations thereof.
• a reactor or outer tube having an inner wall surface and an outer wall surface, such as a reformer tube, may house
• reactor components such as vertically stacked fans or monoliths, arranged around a centre support
• the diameter of the outer tube is preferably constant along its entire length.
• portions of the tube can have a larger diameter and create bulges or expanded portions in the outer tube.
• he reactor components may be constructed to have a central opening for receiving the centre support and centre section components, such as an expanding centre arrangement including the inner tube, such that the components can be stacked or arranged on the centre support between the outer tube and the expanding centre arrangement .
• he centre support can have a length to
• the centre support may be continuous but is preferably formed from sections, each section being associated with an expanding centre arrangement and a section of the reactor components.
• the centre support can have a bracket, bushing, base plate or the like for providing a stop fitting so the reactor components, such as a fan or monolith, do not slide off the end of the centre support.
• the base plate can be located at or near the bottom end of the centre support and can have a shape and diameter or dimensions to permit ease of install in the outer tube.
• the stop plate can have a circular shape with a diameter about the same or less than the inner diameter of the outer tube.
• the centre support can be preloaded with any number of reactor components before being inserted into the outer tube.
• the components can be stacked vertically, one on top of another as shown, to form layers of reactor components, either vertically or in alternative ways such as horizontal to accommodate orientation of a reactor or certain technology requirements.
• Washers can be inserted between one or more reactor components (e.g., fans) as desired, for example, each fan can be separated by a washer wherein the washer creates an open space between the components.
• Stacked reactor- components which have a typical height in the range 8mm to 100mm, can be arranged vertically as desired to create a subassembly with height in the range 15cm to 1.5m.
• Each sub-assembly may be formed on a section of centre support. Once installed, the sections of centre support may combine to form a continuous centre support .
• the section of the centre support may extend beyond one end of the preloaded reactor components of the sub-assembly, thus providing a protruding portion that can be gripped during installation of the subassembly into the outer tube.
• the centre support section may include an open-ended hollow portion at an opposite end of the section to the protruding portion.
• the protruding portion of one section may fit into the hollow portion of an adjacent section so that the reactor components of ad acent sub-assemblies are separated by less than the length of the protruding portion.
• the prot uding portion of one section may fit into the hollow portion of an adjacent section so that the reactor components, including for example the washers if present, of adjacent, sub-assemblies form a continuous stack .
• the reactor components can be, for example, fans or
• the reactor components can be catalyst supports, such as fans, coils or monoliths having one or more catalyst coatings. Washers used in connection with the components can also have a catalyst coating to effectively distribute cata1yst contact with the fluid f1owing through the reactor .
• Catalytic material is known in the art and can include nickel, palladium, platinum, zirconium, rhodium, ruthenium, iridium, cobalt and oxides of aluminium, cerium, and
• the catalyst supports can be expandable in the radial direction such that the supports can be pushed outward radially to the outer tube.
• the reactor components can occupy a portion or substantially the enti e annular space between the outer tube and the inner tube.
• the components when expandable and in the collapsed state, have a diameter less than the outer tube. In the expanded position, the component s can be in direct contact with the outer tube or create a small gap between the outer tube and the outer diameter face of the components. The gap between the outer edge diameter face of the reactor
• components and the inner wall surface of the reactor tube can be at least 0.2, 0.5, 1, 2, 3, 5, 10 or 15mm.
• the gap is preferably not more than 3, 6, 10, 15, 20 or 25mm and preferably in the range of 0.5 to 6mm, and more preferably 1 to 3mm.
• the gap prorriot.es heat transfer and forces fluid flow traveling toward the inner wall surface of the reactor wall to be directed back towards the inner portion of the reactor.
• Spacers such as a washer, wire, ring, loop or the like, can be used to ensure desirable gap spacing between the outer diameter edge or face of the monoliths or fans and the inner wall surface of the reactor tube.
• Fluid such as gas or liquid
• Fluid to be reacted generally flows vertically, either up- flow or down-flow as desired, through the reactor tube and through each component arranged on the centre support, preferably outside the inner tube.
• Reactor components direct fluid flow in other non-vertical directions to increase heat transfer, for example fans can direct, or guide fluid flow radially (perpendicular to the overall vertical direction) towards the reactor tube wall.
• One or more monoliths or fans can be in contact or close proximity of the inner wall surface of the reactor tube, which effectively transfers heat from the exterior of the reactor to the reactor components and fluid contained therein for promoting endothermic catalytic reactions.
• reactors orientations may in particular be used when structured catalyst elements are employed since such elements may be more easily retained in a horizontal geometry than, say, catalyst pellets.
• the expandable centre arrangement may include the inner tube, which may house the expandable centre arrangement .
• the inner tube can be
• the corrugated or composed of rolled metal sheet or flat sheet rolled in a cylinder such that there is an overlapping section at the point the two ends of the sheet meet. That is, the ends of the rolled sheet overlap and, as force is exerted inside the cylinder or tube, the overlapping portion slides so that the inner tube expands radially outward.
• the inner tube can be made of a foil sheet rolled into a cylinder.
• the overlapping section extends at.
• the inner tube may be a cylinder formed from multiple windings of a sheet of
• the inner tube may be a stand- alone article, or may be formed from, the tails of the spring elements ,
• the spring elements provide tension to the reactor components and urge the inner tube outwards.
• the inner tube contacts the reactor components, such as the expandable catalyst-coated fans. Because the spring elements push radially outward against the inner tube, the inner tube can be in constant contact with the reactor components to prevent or eliminate a gap between the inner diameter of the reactor components and the outer diameter of the inner tube. Reducing or eliminating any gap spacing between the inner diameter of the reactor components and the outer diameter of the inner tube increases the amount of fluid that is directed to the outer portion of the reactor near the reactor tube wall, which can increase heat exchange and reaction
• the force provided by the spring elements can also promote expansion of the reactor components against the outer tube thus maintaining the correct, small, spacing between the reactor components and the outer tube and promoting heat transfer to the fluid passing through the reactor.
• the temperature can increase and the outer tube can creep or expand radially outward away from the reactor components and form a gap between the outer diameter face of the reactor components and the outer tube.
• the tendency of the spring elements to unwrap can force the reactor components outward to reduce or eliminate such a gap.
• the expandable centre arrangement is an expandable centre arrangement according to the first aspect of the invention.
• the expandable centre arrangement is an expandable centre arrangement according to the first aspect of the invention.
• the method comprises: providing an expandable centre arrangement comprising an expansion tube and spring elements arranged inside the expansion tube, inserting the centre arrangement into the reactor, introducing a pressurised gas into the expansion tube so as to expand the expansion tube, wherein the spring elements resist compression of the expansion tube after the pressurised gas is vented.
• a centre support is arranged inside the expansion tube and the spring elements are mounted on the centre support.
• the centre support advantageously increases the strength of the arrangement and provides a place for an installation tool to grip.
• the centre support may also be useful for stacking multiple centre arrangements into the reactor as the centre support of one arrangement may
• the expansion tube is forrried from tail ends of the spring elements wrapping around and overlapping each other.
• the spring elements are sheets of resilient material attached along one edge to the centre support, so that first opposite edges of the sheets are parallel to the centre support, and the axis of the expansion tube and second opposite edges of the sheets arc out from the centre support, to the expansion tube.
• Such an arrangement may be simple to manufacture. It may also be advantageous in that the
• overlapping ends of the sheets have a frictional force between them, which assists in preventing compression of the expansion tube.
• the pressurised air is introduced, the air flows between the overlapping ends of the sheets and lubricates movement of the sheets relative to each, other, thus permitting the expansion tube to expand, both as a result of the pressurised air and the expansion force of the resilient spring elements.
• the pressurised air is stopped and the pressure vents, the sheets are no longer lubricated and the frictional force returns to assist in preventing compression.
• the expansion tube is separate from the spring elements.
• the expansion tube is formed from a thinner material than the spring elements.
• the expansion tube is formed from multiple windings of a sheet of material. It may be that the inner end of the sheet of material comprises corrugations. The corrugations may assist the passage of the air between the windings of the sheet, thus facilitating the lubrication and expansion of the expansion tube when pressurised air is introduced into the expansion tube.
• the centre arrangement is inserted into the reactor using a tool.
• the pressurised gas is introduced via the same tool.
• the arrangement can be installed in a single operation using a single tool.
• the pressurised gas is introduced by blowing pressurised gas into the expansion tube.
• the tool grips the centre support for inserting the centre
• the pressurised gas may, for example, be introduced via the centre support, for example by blowing the gas down a hollow centre support and out through holes in the centre support.
• the pressurised gas may, for example, be introduced directly into the expansion tube, for example by blowing the gas into the end of the expansion tube.
• the spring elements provide an outward biasing force to the expansion tube during the introduction of the pressurised gas.
• the spring elements remain in contact with the expansion tube throughout the introduction of the pressurised gas.
• the method includes placing expandable catalyst support components around the centre arrangement before the arrangement is inserted into the reactor.
• the catalyst support components are placed around the outside of the expansion tube.
• the reactor comprises an outer tube, into which the expandable centre arrangement and its surrounding catalyst support components are inserted.
• the expansion of the expansion tube forces the catalyst support components outwardly against the inner surface of the outer tube. In that way the optimal
• Figure 1 is a view of part of an expandable centre
• Figure 2 is a view of the part of the expandable centre arrangement of Figure 1 with the spring elements wrapped around the centre support prior to insertion into an
• Figure 3 is a view of an expandable centre arrangement according to the invention with the part of Figures 1 and 2 inserted into an expansion tube;
• Figure 4 is a view of the expandable centre arrangement of Figure 3 with structured catalyst components stacked around the expansion tube;
• Figure 5 is a view of an expandable centre arrangement according to the invention.
• Figure 6 is another view of the expandable centre arrangement of Figure 5;
• Figure 7 is a view of an expandable centre arrangement with a structured catalyst component around it;
• Figure 8 is a view of the expandable centre arrangement of Figures 5 and 6 surrounded by a structured catalyst
• Figure 9 is a view of an expandable centre arrangement according to the invention.
• Figure 10 is a view of a construction of an expansion tube.
• the centre support 1 comprises a centre support 1 and four spring elements 2a, 2b, 2c, and 2d connected to the centre support 1.
• the spring elements 2a, 2b, 2c, and 2d are sheet-like elements attached to the support so that the sheet -like elements are aligned with the axial direction of the centre support 1.
• the spring elements 2a, 2b, 2c, and 2d are wrapped around the centre support 1.
• the spring elements 2a, 2b, 2c, and 2d can be temporarily held in the wrapped position with bands 3, for example cable ties. When the bands 3 are released, the spring elements 2a, 2b, 2c, and 2d will tend to unwrap, thus creating an expansive force.
• the spring elements 2a, 2b, 2c and 2d can be held in place with a temporary restraining tube.
• temporary restraining tube has a diameter a little smaller than the diameter of the expansion tube 4 (see Figure 3) .
• the expansion tube 4 is placed over the temporary restraining tube and the temporary restraining tube is then pulled off the spring elements 2a, 2b, 2c and 2d and out of the
• expansion tube 4 Like releasing the bands 3, this permits the spring elements 2a, 2b, 2c and 2d to unwrap and create an expansive force against the interior of the expansion tube .
• the bands 3 have been removed and the centre support 1, with the spring elements 2a, 2b, 2c, and 2d wrapped around it has been inserted into an expansion tube 4.
• the spring elements 2a, 2b, 2c, and 2d tend to unwrap and thus press outwardly on the expansion tube 4.
• structured catalyst-coated components 5 can be stacked.
• One such component 5 is shown in Figure 3.
• the structured catalyst-coated components 5 are expandable and the action of the spring elements 2a, 2b, 2c, and 2d trying to unwrap presses outwardly on the expansion tube 4, which in turn presses outwardly against the structured catalyst-component 5.
• Foil bands 3' are wrapped around the expansion tube 4.
• the foil bands 3' are temporary bands that hold the expansion tube until the structured catalyst-coated components 5 are in place. As the structured catalyst-coated components i> are stacked onto the expansion tube 4 the foil bands 3' are slid up and off the expansion tube 4.
• a centre arrangement comprises a centre support
• the spring elements 12a, 12b, 12c, and 12d are sheet-like elements aligned with the axial direction of the centre support 11.
• the spring elements 12a, 12b, 12c, and 12d are resilient spring elements and arc outward from the centre support 11. The arc creates a spring effeet so that the resilient spring elements 12a, 12b, 12c, and 12d can bias an expansion tube outwardly away from the centre support. 11.
• the centre support 11 comprises an array of holes 16.
• a blast of air can be provided down the cavity surrounding the centre support 11 in which the spring elements 12a, 12b, 12c and 12d are located (the so-called vane cavity) . That blast of air may carry out the same lubrication and expansion function as the blast through the holes 16.
• the spring elements 12a, 12b, 12c and 12d are in their final position, with a structured catalyst- coa ed component 15 in place around the outside of the centre arrangement.
• the expansion tube 14 is formed from the tail ends of the spring elements 12a, 12b, 12c and 12d wrapping around and overlapping each other.
• a centre arrangement includes a centre support
• the centre support 111 is a square box section support.
• the spring elements 12a, 12b, 12c and 12d are welded onto the centre support 111 in the region of the corners of the box section. While the spring elements may also be welded to the centre supports 1 and 11 above, the use of the square box section centre support 111 with the spring elements 12a, 12b, 12c and 12d welded in the regions of the corners may result in a robust arrangement that is easy to manufacture .
• an expansion tube is formed from a sheet of material 220, for example steel.
• the sheet 220 has
• corrugations 221 along an edge.
• the sheet 220 is rolled into a cylinder, with the corrugations 221 at an inner edge.
• pressurised air, or another gas is introduced into the tube, the corrugations 221 facilitate the passage of the air between the layers of the sheet 220.
• the operation of the centre arrangement is similar for all of the above embodiments.
• the centre arrangement is assembled by wrapping the spring elements 2, 12, 112 around the centre support 1, 11, 111. If the expansion tube 4 is a separate tube, the centre arrangement is inserted into the expansion tube 4. In a typical installation process the spring elements 2, 12, 112 are tightly wound around the centre support and inserted using considerable force into a temporary
• the expansion tube 4 is slipped over the temporary restraining tube and the temporary tube is then pulled off the spring elements 2, 12, 112 and out of the expansion tube 4.
• the structured catalyst-coated components 5, 15 are stacked around the outside of the expansion tube 4, 14 to create a sub-assembly and the sub-assembly is inserted into the reactor tube.
• Preferably air is blown down the centre support 1, 11, 111 to force the centre arrangement and the structured catalyst-coated components 5, 15 to expand to press into intimate contact with the reactor tube.
• the air may also be blown down the vane cavity.
• the air can be blown using a tool which fits onto a protruding portion of the centre support 1, 11, 111.
• the tool can be the same tool that is used to grip the centre support 1, 11, 111 while lowering the sub-assembly into the reactor tube.
• the centre arrangement can also be expanded by twisting on the cen re support 11, particularly in embodiments where the expansion tube 14 is formed from overlapping ends of the spring elements 12a, 12b, 12c and 12d, with tabs 17 inserted into the structured catalyst-coated components 15.

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• 2017
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