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WO2018234975A1 - Conceptions de réacteur améliorées pour réactions catalytiques hétérogènes - Google Patents

Conceptions de réacteur améliorées pour réactions catalytiques hétérogènes Download PDF

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Publication number
WO2018234975A1
WO2018234975A1 PCT/IB2018/054475 IB2018054475W WO2018234975A1 WO 2018234975 A1 WO2018234975 A1 WO 2018234975A1 IB 2018054475 W IB2018054475 W IB 2018054475W WO 2018234975 A1 WO2018234975 A1 WO 2018234975A1
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WIPO (PCT)
Prior art keywords
bed
zone
cross sectional
intermediate bed
catalyst
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Ceased
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PCT/IB2018/054475
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English (en)
Inventor
Sivadinarayana Chinta
Miasser AL-GHAMDI
Atul Pant
Ravichander Narayanaswamy
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SABIC Global Technologies BV
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SABIC Global Technologies BV
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Publication of WO2018234975A1 publication Critical patent/WO2018234975A1/fr
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    • 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
    • B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
    • B01J8/24—Chemical 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
    • B01J8/26—Chemical 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 two or more fluidised beds, e.g. reactor and regeneration installations
    • 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
    • B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
    • B01J8/24—Chemical 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
    • B01J8/26—Chemical 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 two or more fluidised beds, e.g. reactor and regeneration installations
    • B01J8/28—Chemical 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 two or more fluidised beds, e.g. reactor and regeneration installations the one above the other
    • 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
    • B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
    • B01J8/24—Chemical 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
    • B01J8/42—Chemical 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
    • 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
    • B01J2208/02—Processes carried out in the presence of solid particles; Reactors therefor with stationary particles
    • B01J2208/023—Details
    • B01J2208/024—Particulate material
    • B01J2208/025—Two or more types of catalyst
    • 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
    • B01J2219/00002—Chemical plants
    • B01J2219/00027—Process aspects
    • B01J2219/00033—Continuous processes
    • 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
    • B01J2219/18—Details relating to the spatial orientation of the reactor
    • B01J2219/185—Details relating to the spatial orientation of the reactor vertical

Definitions

  • the present disclosure relates to reactor designs for heterogeneous catalytic reactions, and methods of using same; more specifically reactors comprising catalysts bed configurations for heterogeneous catalytic reactions, and methods of using same.
  • Some heterogeneous catalytic reactions require elevated temperatures in the catalyst bed; and providing these elevated temperatures can be energy intensive, and thus costly.
  • a significant amount of heat of reaction can be lost to the reactor walls and surroundings. This reaction heat can be lost due to radiation from the catalyst bed inlet and outlet cross-section surfaces, as well as due to conduction to the reactor wall. This loss of heat of reaction changes the surface temperature of the catalyst, which in turn can lead to reduced conversion and selectivity.
  • a process comprising (a) feeding a reactant mixture to a continuous flow fixed- bed tubular reactor, wherein the reactor comprises a catalyst bed disposed therein, and wherein a reactor wall inner surface and a catalyst bed outer surface define an annular space along at least a portion of a length of the catalyst bed, (b) exothermically reacting the reactant mixture in the catalyst bed via a heterogeneous catalytic reaction to produce a product mixture, wherein the product mixture comprises one or more reaction products, and (c) recovering at least one reaction product from the product mixture, wherein the catalyst bed comprises a bed inlet, a bed outlet, a first intermediate bed zone, and a second intermediate bed zone, wherein the first intermediate bed zone and the second intermediate bed zone are disposed between the bed inlet and the bed outlet, wherein the second intermediate bed zone is downflow of the first intermediate bed zone, wherein the bed inlet is characterized by a bed inlet surface area, wherein the bed outlet is characterized by a bed outlet surface
  • a reactor system comprising a continuous flow fixed-bed tubular reactor housing a catalyst bed, a reactant mixture flowing into the catalyst bed, a product mixture flowing out of the catalyst bed, wherein the reactor is configured to receive the reactant mixture and to produce the product mixture via an exothermic heterogeneous catalytic reaction in the catalyst bed
  • the catalyst bed comprises a bed inlet, a bed outlet, a first intermediate bed zone, a second intermediate bed zone, and a third intermediate bed zone, wherein the first intermediate bed zone and the second intermediate bed zone are disposed between the bed inlet and the bed outlet, wherein the second intermediate bed zone is downflow of the first intermediate bed zone, wherein the third intermediate bed zone is disposed between the first intermediate bed zone and the second intermediate bed zone, wherein the third intermediate bed zone is downflow of the first intermediate bed zone, wherein the third intermediate bed zone is upflow of the second intermediate bed zone, wherein a reactor wall inner surface and an outer surface of the first intermediate bed zone define a first annular space, wherein
  • Also disclosed herein is a process comprising (a) feeding a reactant mixture to a continuous flow fixed-bed tubular reactor, wherein the reactor comprises a catalyst bed disposed therein, and wherein a reactor wall inner surface and a catalyst bed outer surface define an annular space, (b) non-exothermically or exothermically reacting the reactant mixture in the catalyst bed via a heterogeneous catalytic reaction to produce a product mixture, wherein the product mixture comprises one or more reaction products, and (c) recovering at least one reaction product from the product mixture, wherein the catalyst bed comprises a bed inlet, a bed outlet, a first intermediate bed zone, and a second intermediate bed zone, wherein the first intermediate bed zone and the second intermediate bed zone are disposed between the bed inlet and the bed outlet, wherein the second intermediate bed zone is downflow of the first intermediate bed zone, wherein the bed inlet is characterized by a bed inlet surface area, wherein the bed outlet is characterized by a bed outlet surface area, wherein the first intermediate bed
  • Figure 1 displays a configuration of a reactor comprising a catalyst bed for an exothermic heterogeneous catalytic reaction
  • Figure 2 displays another configuration of a reactor comprising a catalyst bed for an exothermic heterogeneous catalytic reaction
  • Figure 3 displays yet another configuration of a reactor for an exothermic heterogeneous catalytic reaction
  • Figure 4 displays a configuration of a reactor comprising a catalyst bed for a non-exothermic or exothermic heterogeneous catalytic reaction for minimizing side reactions.
  • processes comprising (a) feeding a reactant mixture to a continuous flow fixed-bed tubular reactor, wherein the reactor comprises a catalyst bed disposed therein, wherein a reactor wall inner surface and a catalyst bed outer surface define an annular space along at least a portion of a length of the catalyst bed, and wherein the catalyst bed is characterized by a shape selected from the group consisting of a prolate spheroidal shape, an oblate spheroidal shape, a spherical shape, a shape of two truncated cones joined at their bases, and combinations thereof; (b) exothermically reacting the reactant mixture in the catalyst bed via a heterogeneous catalytic reaction to produce a product mixture, wherein the product mixture comprises one or more reaction products; and (c) recovering at least one reaction product from the product mixture.
  • the heterogeneous catalytic reactions can comprise reactions that are characterized by (e.g., require) a short contact time, such as a contact time of less than about 5 ms.
  • the heterogeneous catalytic reaction can comprise a catalytic partial oxidation (CPO) reaction for the production of syngas.
  • the heterogeneous catalytic reaction can comprise a "millisecond regime"- CPO (MSR-CPO) reaction, wherein the MSR-CPO reaction is characterized by a contact time of less than about 5 ms.
  • Also disclosed herein are processes comprising (a) feeding a reactant mixture to a continuous flow fixed-bed tubular reactor, wherein the reactor comprises a catalyst bed disposed therein, wherein a reactor wall inner surface and a catalyst bed outer surface define an annular space, and wherein the catalyst bed is characterized by an "hourglass"-type shape, as will be described in more detail later herein; (b) non- exothermically or exothermically reacting the reactant mixture in the catalyst bed via a heterogeneous catalytic reaction to produce a product mixture, wherein the product mixture comprises one or more reaction products; and (c) recovering at least one reaction product from the product mixture.
  • the terms “inhibiting” or “reducing” or “preventing” or “avoiding” or any variation of these terms include any measurable decrease or complete inhibition to achieve a desired result.
  • the term "effective,” means adequate to accomplish a desired, expected, or intended result.
  • the terms “comprising” (and any form of comprising, such as “comprise” and “comprises"), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “include” and “includes”) or “containing” (and any form of containing, such as “contain” and “contains”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.
  • a reactor 101 for an exothermic heterogeneous catalytic reaction is disclosed.
  • the reactor 101 generally comprises a reactor wall 10; and a catalyst bed 20.
  • the reactor 102 generally comprises a reactor wall 10; and a catalyst bed 20.
  • the reactor 103 generally comprises a reactor wall 10; and one or more structural elements 28.
  • a reactor 200 for a non-exothermic or exothermic heterogeneous catalytic reaction is disclosed (for minimizing side reactions).
  • the reactor 200 generally comprises a reactor wall 10; and a catalyst bed 30.
  • Common reference numerals refer to common components present in one or more of the Figures, and the description of a particular component is generally applicable across respective Figures wherein the component is present, except as otherwise indicated herein.
  • the reactor (101, 102, 103, 200) can comprise a continuous flow fixed-bed tubular reactor having a catalyst bed (20, 30) disposed therein.
  • the x axis indicates the direction of the cross sections described herein. As will be appreciated by one of skill in the art, and with the help of this disclosure, all cross sections referenced herein are taken parallel to the x axis, and perpendicular to the y axis. Further, for purposes of the disclosure herein, the y axis is parallel to the general direction of the flow through the continuous flow reactor, which is indicated by the flow arrow 15.
  • the y axis can be vertical, it should be understood that it is not necessary for the y-axis to be vertical; the y axis can have any suitable position, such as vertical, horizontal, slanted, semi-vertical, semi-horizontal, etc., for example with respect to a surface that the reactor is placed on.
  • Figures 1 and 2 display examples of reactor configurations (101, 102) wherein the catalyst bed 20 can comprise a structured catalyst (as will be described in more detail later herein) which can retain a desired shape in the absence of reactor internals (e.g., structural elements); such as for example a prolate spheroidal shape, an oblate spheroidal shape, a spherical shape, a shape of two truncated cones joined at their bases, and the like, or combinations thereof.
  • a structured catalyst as will be described in more detail later herein
  • reactor internals e.g., structural elements
  • the reactor 103 configuration depicted in Figure 3 does not show the catalyst bed within the reactor (for clarity purposes)
  • the reactor 103 can comprise any suitable catalyst bed, such as for example a catalyst bed having a configuration/shape similar to a configuration/shape of the catalyst bed 20 shown in Figure 2.
  • catalyst bed 20 in Figure 2 can comprise a structured catalyst in the shape of two truncated cones joined at their bases; while a catalyst bed in the configuration of Figure 3 can comprise a non-structured catalyst in the shape of two truncated cones joined at their bases, wherein such shape is configured by reactor internals in Figure 3.
  • reactor internals e.g., structural elements 28
  • the reactor internals (e.g., structural elements 28) as depicted in Figure 3 can be any suitable reactor internal, such as a solid reactor internal; a semi-solid reactor internal; a hollow reactor internal; a semi-hollow reactor internal; a reactor internal comprising a refractory material; and the like; or combinations thereof; wherein the reactor internal is configured to allow a catalyst (e.g., non-structured catalyst) to achieve and retain a desired shape; such as for example a prolate spheroidal shape, an oblate spheroidal shape, a spherical shape, a shape of two truncated cones joined at their bases, and the like, or combinations thereof.
  • a catalyst e.g., non-structured catalyst
  • the reactor can be any suitable tubular reactor.
  • tubular reactors comprise a reactor housing, which can be any suitable reactor housing, such as a cylindrical pipe (e.g., reactor wall or reactor shell 10) that provides a structure that encloses or encapsulated the catalyst bed (e.g., fixed-bed).
  • the reactor can be designed to withstand process conditions, such as pressure, temperature, reactants, reaction products, etc.
  • the reactor e.g., reactor wall 10) can comprise any suitable metallurgy that enables the necessary process conditions.
  • the catalyst bed 20 can comprise a bed inlet 26, a bed outlet 27, a first intermediate bed zone 21, and a second intermediate bed zone 22; wherein the first intermediate bed zone 21 and the second intermediate bed zone 22 are disposed between the bed inlet 26 and the bed outlet 27; wherein the second intermediate bed zone 22 is downflow of the first intermediate bed zone 21; wherein the bed inlet is characterized by a bed inlet surface area; wherein the bed outlet is characterized by a bed outlet surface area; wherein the first intermediate bed zone is characterized by a first intermediate bed cross sectional area; and wherein the second intermediate bed zone is characterized by a second intermediate bed cross sectional area.
  • a length of the catalyst bed is defined as the distance between the bed inlet and the bed outlet, wherein the distance is parallel to the y axis.
  • a cross sectional area refers to the surface area of a cross section of the bed, wherein the cross section of the bed can be taken at any point along the y axis (along a length of the bed or zone thereof).
  • Various geometries for the cross sections disclosed herein are contemplated, such as, but not limited to circular, semi-circular, ovoid, square, triangular, trilobe, hexagonal, any regular-shaped form with more than three sides, any irregular-shaped form, and the like, or combinations thereof.
  • the diameter of a cross section is defined as the longest distance across that cross section.
  • the diameter is any straight line segment passing through the center of the circle; for an oval (ellipse), the diameter is the longest straight line segment passing through the center of the oval; for a square, the diameter is the square diagonal (e.g., the segment line connecting two opposing square corners); etc.
  • a catalyst bed inlet refers to the portion of the outer surface of the first intermediate bed zone (e.g., zone 21, zone 31) that the reactant mixture flowing through the reactor contacts first, wherein such portion of the outer surface of the first intermediate bed zone is substantially parallel to the x axis.
  • a surface substantially parallel to the x axis refers to a surface that deviates from being parallel to the x axis within less than about 20 degrees; or (as in the case of spherical or spheroidal surfaces) a surface wherein any tangent to the surface deviates from being parallel to the x axis within less than about 20 degrees.
  • the bed inlet 26 is located at the apex of the spheroidal shape that characterizes the first intermediate bed zone 21.
  • a surface area of a bed inlet located at the apex of a prolate spheroidal shaped bed is smaller than a surface area of a bed inlet of a spherical shaped catalyst bed, and a surface area of a bed inlet of a spherical shaped catalyst bed is smaller than a surface area of a bed inlet located at the apex of an oblate spheroidal shaped bed.
  • the bed inlet 26 is the top of the truncated conical shape that characterizes the first intermediate bed zone 21.
  • a catalyst bed outlet refers to the portion of the outer surface of the second intermediate bed zone (e.g., zone 22, zone 32) that is the furthest away from the catalyst bed inlet (e.g., bed inlet 26, bed inlet 36), wherein such portion of the outer surface of the second intermediate bed zone is substantially parallel to the x axis.
  • the bed outlet 27 is located at the apex of the spheroidal shape that characterizes the second intermediate bed zone 22.
  • the bed outlet 27 is the top of the truncated conical shape that characterizes the second intermediate bed zone 22.
  • the bed inlet and the bed outlet of a catalyst bed can comprise an aperture or opening in a structure (e.g., structural element) located inside the reactor, wherein such structure is configured to enclose the catalyst bed and provide for a fixed bed inside the reactor; and wherein the corresponding aperture allows for flow into the catalyst bed and out of the catalyst bed, respectively.
  • a surface area of the bed inlet and the bed outlet refers to the surface area of the corresponding aperture.
  • the bed inlet surface area and the bed outlet surface area can be the same or different.
  • the reactor is characterized by a reactor wall inner surface.
  • the catalyst bed is characterized by a catalyst bed outer surface.
  • a reactor wall inner surface and a catalyst bed outer surface can define an annular space along at least a portion of a length of the catalyst bed.
  • the annular space (e.g., as illustrated in Figures 1 and 2) is discontinuous.
  • the first intermediate bed cross sectional area increases along the first intermediate bed zone 21 in the direction of the flow 15 through the reactor.
  • an increase in the first intermediate bed cross sectional area can be continuous along the first intermediate bed zone 21 or portion thereof in the direction of the flow 15 through the reactor.
  • an increase in the first intermediate bed cross sectional area can be step-wise along the first intermediate bed zone 21 or portion thereof in the direction of the flow 15 through the reactor (e.g., the first intermediate bed cross sectional area can increase along some portions or regions of the first intermediate bed zone 21 in the direction of the flow 15 through the reactor, and stay the same along yet other portions of the first intermediate bed zone 21).
  • the first intermediate bed cross sectional area of the first intermediate bed zone 21 is greater than the bed inlet surface area, the bed outlet surface area, or both.
  • a reactor wall inner surface and an outer surface of the first intermediate bed zone 21 define a first annular space 24.
  • the first annular space 24 can provide for staged addition of a reactant mixture to the catalyst bed 20, as will be described in more detail later herein.
  • the second intermediate bed cross sectional area decreases along the second intermediate bed zone 22 in the direction of the flow 15 through the reactor.
  • a decrease in the second intermediate bed cross sectional area can be continuous along the second intermediate bed zone 22 or portion thereof in the direction of the flow 15 through the reactor.
  • a decrease in the second intermediate bed cross sectional area can be step-wise along the second intermediate bed zone 22 or portion thereof in the direction of the flow 15 through the reactor (e.g., the second intermediate bed cross sectional area can decrease along some portions or regions of the second intermediate bed zone 22 in the direction of the flow 15 through the reactor, and stay the same along yet other portions of the second intermediate bed zone 22).
  • the second intermediate bed cross sectional area of the second intermediate bed zone 22 is greater than the bed inlet surface area, the bed outlet surface area, or both.
  • a reactor wall inner surface and an outer surface of the second intermediate bed zone 22 define a second annular space 25.
  • the first annular space 24 and/or the second annular space 25 can provide for a portion of the reactant mixture to by-pass a portion of the catalyst bed 20.
  • the first annular space 24 and/or the second annular space 25 are characterized by a variable annular cross sectional area.
  • the first annular space 24 and/or the second annular space 25 can provide for an intentional by-pass/separation of reactants (e.g., reactant mixture) and catalyst (e.g., catalyst bed), and can control the extent of the reaction (e.g., heterogeneous catalytic reaction) by varying the annular cross sectional area.
  • the catalyst bed 20 can further comprise a third intermediate bed zone 23; wherein the third intermediate bed zone 23 is disposed between the first intermediate bed zone 21 and the second intermediate bed zone 22; wherein the third intermediate bed zone 23 is downflow of the first intermediate bed zone 21; wherein the third intermediate bed zone 23 is upflow of the second intermediate bed zone 22; and wherein the third intermediate bed zone 23 is characterized by a third intermediate bed cross sectional area.
  • the third intermediate bed cross sectional area is substantially constant along the third intermediate bed zone 23.
  • an area such as a cross sectional area (e.g., third intermediate bed cross sectional area) is considered substantially constant if it varies by less than 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.01%, 0.001%, or less, along a length of a bed zone (e.g., third intermediate bed zone 23).
  • the third intermediate bed cross sectional area is greater than the first intermediate bed cross sectional area, the second intermediate bed cross sectional area, or both.
  • the third intermediate bed zone 23 contacts an inner surface of the reactor wall 10.
  • the third intermediate bed zone 23 provides for a discontinuous annular space, i.e., separates the first annular space 24 from the second annular space 25.
  • first annular space 24 and the second annular space 25 can be separated from each other by the catalyst bed 20 (e.g., first intermediate bed zone 21 and/or the second intermediate bed zone 22) contacting the reactor wall 10; structural internal elements present in the reactor; etc.
  • a length of the first intermediate bed zone 21, a length of the second intermediate bed zone 22, a length of the third intermediate bed zone 23, or combinations thereof are effective to provide for a desired contact time, a desired conversion, a desired selectivity, and the like, or combinations thereof.
  • the lengths of the first intermediate bed zone 21, the second intermediate bed zone 22, and the third intermediate bed zone 23 can be altered (e.g., modified) to provide for a desired contact time for conversion and selectivity to desired products.
  • the length of the third intermediate bed zone 23 is 0 (zero).
  • the catalyst bed 20 can be characterized by a prolate spheroidal shape, wherein a distance between the bed inlet 26 and the bed outlet 27 (e.g., along the y axis; along a length of the catalyst bed, etc.) is greater than a diameter of a cross section of the first intermediate bed zone 21, a diameter of a cross section of the second intermediate bed zone 22, or both.
  • the distance between the bed inlet 26 and the bed outlet 27 is greater than an inner reactor diameter, a diameter of a cross section of the third intermediate bed zone 23, or both.
  • the catalyst bed 20 can be characterized by an oblate spheroidal shape, wherein a distance between the bed inlet 26 and the bed outlet 27 (e.g., along the y axis; along a length of the catalyst bed 20, etc.) is smaller than an inner reactor diameter, a diameter of a cross section of the third intermediate bed zone 23, or both.
  • the catalyst bed 20 can be characterized by a spherical shape, wherein a distance between the bed inlet 26 and the bed outlet 27 is about the same as an inner reactor diameter, a diameter of a cross section of the third intermediate bed zone 23, or both.
  • the catalyst bed 20 can be characterized by a shape of two truncated cones joined at their bases.
  • the first intermediate bed zone 21 and/or the second intermediate bed zone 22 can be characterized by a truncated conical shape, or portion thereof; half of a spherical shape, or portion thereof; half of a prolate spheroidal shape, or portion thereof; half of an oblate spheroidal shape, or portion thereof; and the like; or combinations thereof.
  • the third intermediate bed zone 23 can be characterized by a cylindrical shape.
  • an overall shape of the catalyst bed 20 can be symmetrical with respect to an x axis (e.g., a shape of the first intermediate bed zone 21 is substantially the same as a shape of the second intermediate bed zone 22, that is zone 21 and zone 22 are disposed in a mirror image fashion between the bed inlet 26 and the bed outlet 27).
  • an overall shape of the catalyst bed 20 can be asymmetrical with respect to an x axis (e.g., a shape of the first intermediate bed zone 21 is different than a shape of the second intermediate bed zone 22).
  • the catalyst bed 20 shape can be provided by structural elements (e.g., structural elements 28) inside the reactor; a structured catalyst; or both structural elements and a structured catalyst.
  • the first annular space 24, the second annular space 25, or both can comprise one or more structural elements 28 that are configured to provide for a catalyst bed configuration (e.g., catalyst bed shape) that is characterized by a non-uniform cross section along the catalyst bed 20.
  • the structural elements 28 can have any suitable shape, size, number, configuration, etc. effective for providing the desired catalyst bed configuration (e.g., catalyst bed shape).
  • the catalyst bed 20 comprises a packed catalyst (as opposed to a structured catalyst)
  • the catalyst can be held inside the catalyst bed 20 by any suitable methodology, such as for example by structural elements 28 that can further comprise screens.
  • structural elements 28 can provide for the general shape or configuration of the catalyst bed 20, and screens can be used at the bed inlet 26 and/or the bed outlet 27 to provide for retaining the catalyst in a fixed-bed configuration of the desired shape.
  • a packed catalyst can comprise catalyst powders, catalyst particles, etc.
  • catalyst particle shapes suitable for use in the present disclosure include cylindrical, discoidal, spherical, tabular, ellipsoidal, equant, irregular, cubic, acicular, and the like, or combinations thereof.
  • the catalyst bed 20 can comprise a structured catalyst that provides for a catalyst bed configuration (e.g., catalyst bed shape) that is characterized by a non-uniform cross section along the catalyst bed 20.
  • the structured catalyst can comprise a metallic monolithic catalyst, a non-metallic monolithic catalyst, or both.
  • a monolithic catalyst is a large single catalytic entity, and can comprise a honeycomb monolith, a ceramic foam monolith, or both.
  • Monolithic catalysts suitable for use in the present disclosure can employ variable channels or cells to allow for variable flow dynamics (e.g., to match the required flow dynamics through the catalyst bed).
  • the first annular space 24, the second annular space 25, or both can comprise a radiation shield (e.g., thermal shield).
  • the radiation shield can have any suitable configuration and comprise any suitable material effective for retaining process heat within the catalyst bed.
  • the radiation shield can comprise a reflective plate.
  • a process e.g., a process for conducting an exothermic reaction, such as an exothermic heterogeneous catalytic reaction
  • a process for conducting an exothermic reaction can comprise (a) feeding a reactant mixture to a continuous flow fixed-bed tubular reactor (e.g., reactor 101, 102, 103), wherein the reactor comprises a catalyst bed 20 disposed therein; (b) exothermically reacting the reactant mixture in the catalyst bed 20 via a heterogeneous catalytic reaction to produce a product mixture, wherein the product mixture comprises one or more reaction products; and (c) recovering at least one reaction product from the product mixture.
  • a continuous flow fixed-bed tubular reactor e.g., reactor 101, 102, 103
  • process heat can be lost due to conduction at an entrance (e.g., bed inlet, such as bed inlet 26) and exit (e.g., bed outlet, such as bed outlet 27) of the catalyst (e.g., catalyst bed), as well as radiation from the entrance and exit catalyst surfaces.
  • heat radiation is proportional to the surface area (e.g., a surface area of the catalyst bed that can radiate heat, such as an entrance (inlet) surface area and/or an exit (outlet) surface area).
  • the catalyst bed 20 configurations as disclosed herein can provide both for reducing the surface area that allows for radiation heat loss (e.g., reducing the bed inlet surface area, the bed outlet surface area, or both), and a desired catalyst loading to meet the desired productivity.
  • a process e.g., a process for conducting an exothermic reaction, such as an exothermic heterogeneous catalytic reaction
  • a process for conducting an exothermic reaction can be characterized by a bed inlet heat loss and/or a bed outlet heat loss that is decreased when compared to a bed inlet heat loss and/or a bed outlet heat loss of an otherwise similar process conducted with a fixed catalyst bed wherein the first intermediate bed cross sectional area and the second intermediate bed cross sectional area are not greater than the bed inlet surface area, the bed outlet surface area, or both.
  • a process e.g., a process for conducting an exothermic reaction, such as an exothermic heterogeneous catalytic reaction
  • a bed inlet heat loss and/or a bed outlet heat loss that is decreased by equal to or greater than about 5%, alternatively equal to or greater than about 10%, or alternatively equal to or greater than about 15%, when compared to a bed inlet heat loss and/or a bed outlet heat loss of an otherwise similar process conducted with a fixed catalyst bed wherein the first intermediate bed cross sectional area and the second intermediate bed cross sectional area are not greater than the bed inlet surface area, the bed outlet surface area, or both.
  • a fluid flow velocity can vary within the catalyst bed 20 along the y axis.
  • a catalyst bed configuration e.g., catalyst bed shape
  • a non-uniform cross section along a length of the catalyst bed 20 can provide for a non-uniform fluid flow velocity along the catalyst bed 20, owing to the non-uniform cross section.
  • the fluid flow velocity can be increased (e.g., faster flow) at the bed inlet 26 (owing to a small bed inlet surface area) and can decrease along a length of the first intermediate bed zone 21, as a surface area of the cross section increases.
  • reaction rates at the bed inlet 26 are high; and as the fluid flows further into the catalyst bed (in the direction of the flow as indicated by arrow 15), reaction rates decrease owing to a depletion in an amount of reactants.
  • reaction rates decrease owing to a depletion in an amount of reactants.
  • the fluid flow rates are decreased (e.g., slower flow), and the reactants can spend a longer time to contact the catalyst, thereby resulting in higher net conversions, and hence releasing additional heat.
  • varying the fluid flow velocity along the y axis in the catalyst bed can reduce heat losses, for example by allowing the reaction to proceed further into the catalyst bed at meaningful reaction rates, as described herein.
  • the amount of catalyst in the catalyst bed 20 can be varied in the direction of y axis to enhance heat retention in the catalyst bed.
  • the catalyst bed 20 as disclosed herein can provide for better heat retention inside the catalyst bed (e.g., in the middle of the catalyst bed) when compared to an otherwise similar cylindrical shaped catalyst bed that is not characterized by a non-uniform cross section along the catalyst bed.
  • an amount of reactants is decreased, and in order to maintain the necessary temperature, an amount of catalyst is decreased along the second intermediate bed zone 22, by decreasing the cross section, thereby allowing for the reaction that is tailing off to supply enough heat to provide for an uniform temperature across the catalyst bed.
  • staging reactants addition into the catalyst bed 20 can also provide for maintaining a desired heat profile within the catalyst bed; increasing conversion; increasing selectivity; or combinations thereof
  • a first portion of the reactant mixture fed to the reactor can enter the catalyst bed 20 via the bed inlet 26, and a second portion of the reactant mixture fed to the reactor can flow into the first annular space 24 and enter the catalyst bed via an outer surface of the first intermediate bed zone 21.
  • Fresh reactant mixture entering the catalyst bed 20 further along the y axis can provide for enhancing the exothermic reaction, thereby generating more heat at that point in the catalyst bed.
  • a process as disclosed herein conducted with the catalyst bed 20 can be characterized by a conversion that is increased when compared to a conversion of an otherwise similar process conducted with a fixed catalyst bed wherein the first intermediate bed cross sectional area and the second intermediate bed cross sectional area are not greater than the bed inlet surface area, the bed outlet surface area, or both.
  • a process as disclosed herein conducted with the catalyst bed 20 can be characterized by a conversion that is increased by equal to or greater than about 5%, alternatively equal to or greater than about 10%, or alternatively equal to or greater than about 20%, when compared to a conversion of an otherwise similar process conducted with a fixed catalyst bed wherein the first intermediate bed cross sectional area and the second intermediate bed cross sectional area are not greater than the bed inlet surface area, the bed outlet surface area, or both.
  • a process as disclosed herein conducted with the catalyst bed 20 can be characterized by a selectivity to the one or more reaction products that is increased when compared to a selectivity to the one or more reaction products of an otherwise similar process conducted with a fixed catalyst bed wherein the first intermediate bed cross sectional area and the second intermediate bed cross sectional area are not greater than the bed inlet surface area, the bed outlet surface area, or both.
  • a process as disclosed herein conducted with the catalyst bed 20 can be characterized by a selectivity to the one or more reaction products that is increased by equal to or greater than about 5%, alternatively equal to or greater than about 10%, or alternatively equal to or greater than about 20%, when compared to a selectivity to the one or more reaction products of an otherwise similar process conducted with a fixed catalyst bed wherein the first intermediate bed cross sectional area and the second intermediate bed cross sectional area are not greater than the bed inlet surface area, the bed outlet surface area, or both.
  • the reactor 101, 102, 103 can operate under near-isothermal conditions in the catalyst bed 20.
  • the near-isothermal conditions in the catalyst bed 20 can be provided by the catalyst bed configuration (e.g., catalyst bed shape), as disclosed herein.
  • the reactor 101, 102, 103 can operate under non-adiabatic and near-isothermal conditions.
  • non-adiabatic conditions refers to process conditions wherein a reactor is subjected to external heat exchange or transfer (e.g., the reactor is heated; or the reactor is cooled), which can be direct heat exchange and/or indirect heat exchange.
  • adiabatic conditions refers to process conditions wherein a reactor is not subjected to external heat exchange (e.g., the reactor is not heated; or the reactor is not cooled).
  • external heat exchange implies an external heat exchange system (e.g., a cooling system; a heating system) that requires energy input.
  • isothermal conditions generally refer to process conditions wherein the reactor and/or catalyst bed has a substantially constant temperature that can be defined as a temperature that varies by less than about + 10 °C, alternatively less than about + 9 °C, alternatively less than about + 8 °C, alternatively less than about + 7 °C, alternatively less than about + 6 °C, alternatively less than about + 5 °C, alternatively less than about + 4 °C, alternatively less than about + 3 °C, alternatively less than about + 2 °C, or alternatively less than about + 1 °C.
  • the term "near-isothermal conditions” refers to process conditions that allow for a fairly constant temperature of the reactor (e.g., a fairly constant temperature within the catalyst bed), which can be defined as a temperature that varies by less than about + 100 °C, alternatively less than about + 90 °C, alternatively less than about + 80 °C, alternatively less than about + 70 °C, alternatively less than about + 60 °C, alternatively less than about + 50 °C, alternatively less than about + 40 °C, alternatively less than about + 30 °C, alternatively less than about + 20 °C, alternatively less than about + 10 °C, alternatively less than about + 9 °C, alternatively less than about + 8 °C, alternatively less than about + 7 °C, alternatively less than about + 6 °C, alternatively less than about + 5 °C, alternatively less than about + 4 °C, alternatively less than about + 3 °C, alternatively less than about less than about + 100 °C,
  • near-isothermal conditions is understood to include “isothermal conditions.”
  • near-isothermal conditions allow for a temperature variation (e.g., a temperature variation within the reactor; a temperature variation within a catalyst bed) of less than about + 50 °C, alternatively less than about + 25 °C, or alternatively less than about + 10 °C.
  • near- isothermal conditions can be provided by a variety of process and catalyst variables, such as catalyst bed configuration (e.g., catalyst bed shape), reactor configuration, temperature (e.g., heat exchange), pressure, gas flow rates, and the like, or combinations thereof.
  • catalyst bed configuration e.g., catalyst bed shape
  • reactor configuration e.g., temperature
  • pressure e.g., pressure
  • gas flow rates e.g., gas flow rates, and the like, or combinations thereof.
  • the near-isothermal conditions can be further provided by direct heat exchange and/or indirect heat exchange.
  • the near-isothermal conditions can be provided by further cooling the reactor.
  • the near-isothermal conditions can be provided by further heating the reactor.
  • the indirect heat exchange can comprise heating the reactor; or cooling the reactor.
  • the indirect heat exchange can comprise external heat exchange, external coolant fluid cooling, reactive cooling, liquid nitrogen cooling, cryogenic cooling, electric heating, electric arc heating, microwave heating, radiant heating, natural gas combustion, solar heating, infrared heating, and the like, or combinations thereof.
  • reactive cooling can be effected by carrying out an endothermic reaction in a cooling coil/jacket associated with (e.g., located in) the reactor.
  • the direct heat exchange can comprise introducing a cooling agent, such as a diluent, into the reactor, to decrease a reactor temperature, while increasing a temperature of the cooling agent and/or changing the phase of the cooling agent.
  • the cooling agent can be reactive or non-reactive.
  • the cooling agent can be in liquid state and/or in vapor state.
  • the cooling agent can act as a flammability retardant; for example by reducing the temperature inside the reactor, by changing the gas mixture composition, by changing flame speed, by reducing the combustion of hydrocarbons to carbon dioxide; etc.
  • the heterogeneous catalytic reaction (e.g., exothermic heterogeneous catalytic reaction) can comprise an oxidation reaction, a catalytic partial oxidation (CPO) reaction, a "millisecond regime"- CPO (MSR-CPO) reaction, a hydrogenation reaction, an oxidative coupling reaction, an oxidative coupling of methane reaction, an oxidative dehydrogenation reaction, and the like, or combinations thereof.
  • the heterogeneous catalytic reactions can comprise reactions that are characterized by (e.g., require) a short contact time, such as a contact time of less than about 5 ms.
  • An MSR-CPO reaction is generally characterized by a contact time of less than about 5 ms.
  • the heterogeneous catalytic reaction (e.g., exothermic heterogeneous catalytic reaction) can comprise a CPO reaction, wherein the catalyst bed comprises a CPO catalyst.
  • the CPO reaction is based on partial combustion of fuels for the production of syngas, such as various hydrocarbons, and in the case of methane, CPO can be represented by equation (1):
  • the CPO reaction as depicted in equation (1) is an exothermic heterogeneous catalytic reaction (i.e., a mildly exothermic reaction) and it occurs in one step (as opposed to a two-step or multi-step reaction).
  • the CPO reaction as depicted in equation (1) can occur in single reactor unit (as opposed to more than one reactor unit as is the case in conventional processes for syngas production, such as steam methane reforming (SMR) - autothermal reforming (ATR) combinations).
  • homogeneous partial oxidation of hydrocarbons process entails excessive temperatures, long residence times, as well as excessive coke formation, which strongly reduce the controllability of the partial oxidation reaction, and may not produce syngas of the desired quality in a single reaction step and/or a single reactor unit.
  • the CPO reaction is fairly resistant to chemical poisoning, and as such it allows for the use of a wide variety of hydrocarbon feedstocks, including some sulfur containing hydrocarbon feedstocks; which, in some cases, can enhance catalyst life-time and productivity.
  • the hydrocarbons suitable for use in a CPO reaction as disclosed herein can include methane, natural gas, natural gas liquids, associated gas, well head gas, enriched gas, paraffins, shale gas, shale liquids, fuel gas, refinery process gases, fluid catalytic cracking (FCC) off gas (e.g., refinery unit off-gases from FCC), stack gases, hydrocarbons from catalytic naphtha reforming, hydrocarbons from hydrocracking, and the like, or combinations thereof.
  • the hydrocarbons can include any suitable hydrocarbons source.
  • the reactant mixture can comprise CH 4 and O 2 .
  • the oxygen used in the reactant mixture in a CPO process can comprise 100% oxygen (substantially pure O 2 ), oxygen gas (which may be obtained via a membrane separation process), technical oxygen (which may contain some air), air, oxygen enriched air, oxygen-containing gaseous compounds (e.g., NO), oxygen-containing mixtures (e.g., 0 2 /C0 2 , 0 2 /H 2 0, 0 /H 0 /H 0), oxy radical generators (e.g., CH 3 OH, CH 2 0), hydroxyl radical generators, and the like, or combinations thereof.
  • the reactant mixture in a CPO process can be characterized by a methane to oxygen (CFL t /0 2 ) molar ratio of equal to or greater than about 1: 1, alternatively equal to or greater than about 2: 1, alternatively equal to or greater than about 3:1, alternatively from about 1 :1 to about 3: 1, alternatively from about 1.5:1 to about 2.5:1, or alternatively from about 1.6:1 to about 2.2:1.
  • CFL t /0 2 methane to oxygen
  • the CH 4 /0 molar ratio can be adjusted along with other reactor process parameters (e.g., temperature, pressure, flow velocity, etc.) to provide for near-isothermal conditions, as well as a syngas with a desired composition (e.g., a syngas with a desired hydrogen to carbon monoxide (H 2 /CO) molar ratio).
  • a syngas with a desired composition e.g., a syngas with a desired hydrogen to carbon monoxide (H 2 /CO) molar ratio.
  • the CFL t /0 2 molar ratio can also vary with the addition of a diluent to the reactant mixture (e.g., water addition to the reactant mixture, C0 , addition to the reactant mixture, etc.).
  • the reactant mixture in a CPO process can further comprise a diluent, wherein the diluent can further contribute to the near-isothermal conditions via direct heat exchange, as disclosed herein.
  • the diluent can comprise water, steam, inert gases (e.g., argon), nitrogen, carbon dioxide, and the like, or combinations thereof.
  • the diluent is inert with respect to the CPO reaction, e.g., the diluent does not participate in the CPO reaction.
  • some diluents e.g., water, steam, carbon dioxide, etc.
  • some diluents might undergo chemical reactions other than the CPO reaction within the reactor, and can change the composition of the resulting syngas
  • other diluents e.g., nitrogen (N ), argon (Ar)
  • the diluent can be used to vary the composition of the resulting syngas.
  • the diluent can be present in the reactant mixture in an amount of from about 1% to about 99%, alternatively from about 5% to about 50%, or alternatively from about 10% to about 20%, based on the total volume of the reactant mixture.
  • the reactor used for carrying out a CPO reaction can be characterized by a contact time of from about 0.001 milliseconds (ms) to about 1 s, alternatively from about 0.001 ms to about 100 ms, alternatively from about 0.001 ms to about 10 ms, alternatively from about 0.001 ms to about 5 ms, alternatively from about 0.01 ms to about 1.2 ms, or alternatively from about 0.01 ms to about 1 ms.
  • ms milliseconds
  • the contact time of a reactor comprising a catalyst refers to the average amount of time that a compound (e.g., a molecule of that compound) spends in contact with the catalyst (e.g., within the catalyst bed), e.g., the average amount of time that it takes for a compound (e.g., a molecule of that compound) to travel through the catalyst bed.
  • a compound e.g., a molecule of that compound spends in contact with the catalyst (e.g., within the catalyst bed), e.g., the average amount of time that it takes for a compound (e.g., a molecule of that compound) to travel through the catalyst bed.
  • the contact time of less than about 5 ms can be referred to as “millisecond regime” (MSR); and a process or reaction as disclosed herein characterized by a contact time of less than about 5 ms can be referred to as “millisecond regime"- CPO (MSR-CPO) process or reaction, respectively.
  • the reactor used for carrying out a CPO reaction (e.g., reactor 101, 102, 103) can be characterized by a contact time of from about 0.001 ms to about 5 ms, or alternatively from about 0.01 ms to about 1.2 ms.
  • the CPO reaction is a heterogeneous exothermic reaction that is generally conducted in the presence of a CPO catalyst comprising a catalytically active metal, i.e., a metal active for catalyzing the CPO reaction.
  • the catalytically active metal can comprise a noble metal (e.g., Pt, Rh, Ir, Pd, Ru, Ag, and the like, or combinations thereof); a non-noble metal (e.g., Ni, Co, V, Mo, P, Fe, Cu, and the like, or combinations thereof); rare earth elements (e.g., La, Ce, Nd, Eu, and the like, or combinations thereof); oxides thereof; and the like; or combinations thereof.
  • a noble metal is a metal that resists corrosion and oxidation in a water-containing environment.
  • the components of the CPO catalyst e.g., metals such as noble metals, non-noble metals, etc., rare earth elements, can be either phase segregated or combined within the same phase.
  • the CPO catalysts suitable for use in the present disclosure can be supported catalysts and/or unsupported catalysts.
  • the supported catalysts can comprise a support, wherein the support can be catalytically active (e.g., the support can catalyze a CPO reaction).
  • the catalytically active support can comprise a metal gauze or wire mesh (e.g., Pt gauze or wire mesh); a catalytically active metal monolithic catalyst; etc.
  • the supported catalysts can comprise a support, wherein the support can be catalytically inactive (e.g., the support cannot catalyze a CPO reaction), such as Si0 2 ; alumina; a catalytically inactive monolithic support; etc.
  • the supported catalysts can comprise a catalytically active support and a catalytically inactive support.
  • a CPO catalyst can be wash coated onto a support, wherein the support can be catalytically active or inactive, and wherein the support can be a monolith, a foam, an irregular catalyst particle, etc.
  • the CPO catalyst can be a monolith, a foam, a powder, a particle, etc.
  • CPO catalyst particle shapes suitable for use in the present disclosure include cylindrical, discoidal, spherical, tabular, ellipsoidal, equant, irregular, cubic, acicular, and the like, or combinations thereof.
  • the support comprises an inorganic oxide, alpha, beta or theta alumina (AI 2 O 3 ), activated A1 0 3 , silicon dioxide (Si0 2 ), titanium dioxide (Ti0 2 ), magnesium oxide (MgO), zirconium oxide (Zr0 2 ), lanthanum (III) oxide (La 2 0 3 ), yttrium (III) oxide ( ⁇ 2 ⁇ 3), cerium (IV) oxide (Ce0 2 ), zeolites, ZSM-5, perovskite oxides, hydrotalcite oxides, and the like, or combinations thereof.
  • AI 2 O 3 inorganic oxide, alpha, beta or theta alumina
  • the syngas produced under near-isothermal conditions as disclosed herein can comprise hydrogen, carbon monoxide, carbon dioxide, water, and unreacted hydrocarbons.
  • the syngas can be used in a downstream process as recovered from the reactor (e.g., "as is;" without further processing).
  • the syngas can be further processed prior to being used in a downstream process. For example, unreacted hydrocarbons, diluent, etc. can be recovered from the syngas prior to using the syngas in a downstream process.
  • a process for producing syngas as disclosed herein can further comprise (i) recovering at least a portion of the unreacted hydrocarbons from the syngas to yield recovered hydrocarbons, and (ii) recycling at least a portion of the recovered hydrocarbons to the reactor.
  • the syngas can be characterized by a H 2 /CO molar ratio that varies by less than about 20%, alternatively less than about 15%, alternatively less than about 10%, or alternatively less than about 5% (as compared to a desired or targeted H 2 /CO molar ratio), under the near-isothermal operating conditions for a given set of reactor operating conditions, such as pressure and CFL t /0 2 molar ratio.
  • the syngas can be characterized by an M ratio that varies by less than about 20%, alternatively less than about 15%, alternatively less than about 10%, or alternatively less than about 5% (as compared to a desired or targeted M ratio), under the near-isothermal operating conditions for a given set of reactor operating conditions, such as pressure and CFL t /0 2 molar ratio; wherein the M ratio is a molar ratio defined as (H 2 -C0 2 )/(CO+C0 2 ); etc.), for a given set of operating conditions (e.g., pressure, CH 4 /O 2 molar ratio, etc.).
  • Syngas recovered from the reactor can be used for any suitable purpose, such as methanol production, olefins production, aromatics production, liquid hydrocarbons production, liquid hydrocarbons production via a gas to liquids (GTL) process, liquid hydrocarbons production via a Fischer-Tropsch (FT) process, dimethyl ether (DME) production, oxo-synthesis of aliphatic aldehydes and/or alcohols, petrochemicals production, and the like, or combinations thereof.
  • GTL gas to liquids
  • FT Fischer-Tropsch
  • DME dimethyl ether
  • each process that uses syngas for the synthesis of a particular product may benefit from using a syngas with a specific composition (e.g., specific M ratio; specific H 2 /CO molar ratio; etc.).
  • a syngas with a specific composition e.g., specific M ratio; specific H 2 /CO molar ratio; etc.
  • the syngas can be further used for methanol production.
  • at least a portion of the syngas recovered from the reactor can be contacted with a methanol production catalyst in a methanol production unit to produce methanol.
  • the methanol production unit can comprise any reactor suitable for a methanol synthesis reaction from CO and H 2 .
  • the syngas recovered from the reactor can be characterized by a H 2 /CO molar ratio of about 1 :1, wherein at least a portion of the syngas can be used for dimethyl ether (DME) production.
  • DME dimethyl ether
  • the syngas recovered from the reactor can be characterized by a H 2 /CO molar ratio of about 1: 1, wherein at least a portion of the syngas can be used for oxo-synthesis of aliphatic aldehydes and/or alcohols.
  • the alcohol can comprise 2-ethyl hexanol.
  • the syngas recovered from the reactor can be further converted to olefins.
  • the syngas can be converted to alkanes by using a Fisher-Tropsch process, and the alkanes can be further converted by dehydrogenation into olefins.
  • the syngas recovered from the reactor can be further converted to liquid hydrocarbons (e.g., alkanes) by a Fisher-Tropsch process.
  • the liquid hydrocarbons can be further converted by dehydrogenation into olefins.
  • the reactor 200 can comprise a catalyst bed 30, wherein the catalyst bed 30 can comprise a bed inlet 36, a bed outlet 37, a first intermediate bed zone 31, and a second intermediate bed zone 32; wherein the first intermediate bed zone 31 and the second intermediate bed zone 32 are disposed between the bed inlet 36 and the bed outlet 37; wherein the second intermediate bed zone 32 is downflow of the first intermediate bed zone 31 ; wherein the bed inlet is characterized by a bed inlet surface area; wherein the bed outlet is characterized by a bed outlet surface area; wherein the first intermediate bed zone is characterized by a first intermediate bed cross sectional area; and wherein the second intermediate bed zone is characterized by a second intermediate bed cross sectional area.
  • a length of the catalyst bed is defined as the distance between the bed inlet and the bed outlet, wherein the distance is parallel to the y axis.
  • a reactor wall inner surface of reactor 10 and a catalyst bed outer surface of the catalyst bed 30 can define an annular space 34 along at least a portion of a length of the catalyst bed.
  • the annular space (e.g., as illustrated in Figure 4) is continuous.
  • the first intermediate bed cross sectional area decreases along the first intermediate bed zone 31 in the direction of the flow 15 through the reactor.
  • a decrease in the first intermediate bed cross sectional area can be continuous along the first intermediate bed zone 31 or portion thereof in the direction of the flow 15 through the reactor.
  • a decrease in the first intermediate bed cross sectional area can be step-wise along the first intermediate bed zone 31 or portion thereof in the direction of the flow 15 through the reactor (e.g., the first intermediate bed cross sectional area can decrease along some portions or regions of the first intermediate bed zone 31 in the direction of the flow 15 through the reactor, and stay the same along yet other portions of the first intermediate bed zone 31).
  • the first intermediate bed cross sectional area of the first intermediate bed zone 31 is smaller than the bed inlet surface area, the bed outlet surface area, or both.
  • the second intermediate bed cross sectional area increases along the second intermediate bed zone 32 in the direction of the flow 15 through the reactor.
  • an increase in the second intermediate bed cross sectional area can be continuous along the second intermediate bed zone 32 or portion thereof in the direction of the flow 15 through the reactor.
  • an increase in the second intermediate bed cross sectional area can be step-wise along the second intermediate bed zone 32 or portion thereof in the direction of the flow 15 through the reactor (e.g., the second intermediate bed cross sectional area can increase along some portions or regions of the second intermediate bed zone 32 in the direction of the flow 15 through the reactor, and stay the same along yet other portions of the second intermediate bed zone 32).
  • the second intermediate bed cross sectional area of the second intermediate bed zone 32 is smaller than the bed inlet surface area, the bed outlet surface area, or both.
  • the catalyst bed 30 can be characterized by an hourglass-type configuration (e.g., hourglass-type shape), wherein a cross section (e.g., diameter) of the catalyst bed 30 is smaller in the middle (e.g., along the y axis) and it is wider towards the bed inlet 36 and bed outlet 37.
  • an hourglass-type configuration e.g., hourglass-type shape
  • a cross section e.g., diameter
  • the catalyst bed 30 can be characterized by a shape of two truncated cones joined at their tops.
  • the first intermediate bed zone 31 and/or the second intermediate bed zone 32 can be characterized by a truncated conical shape, or portion thereof; half of a spherical shape, or portion thereof; half of a prolate spheroidal shape, or portion thereof; half of an oblate spheroidal shape, or portion thereof; and the like; or combinations thereof.
  • an overall shape of the catalyst bed 30 can be symmetrical with respect to an x axis (e.g., a shape of the first intermediate bed zone 31 is substantially the same as a shape of the second intermediate bed zone 32, that is zone 31 and zone 32 are disposed in a mirror image fashion between the bed inlet 36 and the bed outlet 37).
  • an overall shape of the catalyst bed 30 can be asymmetrical with respect to an x axis (e.g., a shape of the first intermediate bed zone 31 is different than a shape of the second intermediate bed zone 32).
  • the catalyst bed 30 shape can be provided by structural elements inside the reactor; a structured catalyst; or both structural elements and a structured catalyst.
  • the annular space 34 is configured to provide for a catalyst bed configuration (e.g., catalyst bed shape) that is characterized by a non-uniform cross section along the catalyst bed 30.
  • the structural elements inside of the reactor 200 can have any suitable shape, size, number, configuration, etc. effective for providing the desired catalyst bed configuration (e.g., catalyst bed shape).
  • the catalyst bed 30 comprises a packed catalyst (as opposed to a structured catalyst)
  • the catalyst can be held inside the catalyst bed 30 by any suitable methodology, such as for example by structural elements that can further comprise screens.
  • structural elements can provide for the general shape or configuration of the catalyst bed 30, and screens can be used at the bed inlet 36 and/or the bed outlet 37 to provide for retaining the catalyst in a fixed- bed configuration of the desired shape.
  • the catalyst bed 30 can comprise a structured catalyst that provides for a catalyst bed configuration (e.g., catalyst bed shape) that is characterized by a non-uniform cross section along the catalyst bed 30 as disclosed herein.
  • a catalyst bed configuration e.g., catalyst bed shape
  • a process as disclosed herein can comprise (a) feeding a reactant mixture to a continuous flow fixed-bed tubular reactor 200, wherein the reactor 200 comprises a catalyst bed 30 disposed therein, and wherein a reactor wall inner surface and a catalyst bed outer surface define an annular space 34; (b) non-exothermically or exothermically reacting the reactant mixture in the catalyst bed 30 via a heterogeneous catalytic reaction to produce a product mixture, wherein the product mixture comprises one or more reaction products; and (c) recovering at least one reaction product from the product mixture.
  • the term "non-exothermic reaction” includes all reactions that are not exothermic, i.e., all reactions that do not generate heat.
  • Non-limiting examples of non-exothermic or exothermic heterogeneous catalytic reactions suitable for use in the present disclosure include coke formation by dehydrogenation, an oxidation reaction, a catalytic partial oxidation (CPO) reaction, a hydrogenation reaction, cracking of products formed by coupling, further oxidation of CO to CO 2 by unreacted O 2 or water formed in a reaction, and the like, or combinations thereof.
  • CPO catalytic partial oxidation
  • a configuration of a catalyst bed such as catalyst bed 30 can be used for an oxidative coupling reaction, an oxidative coupling of methane reaction, an oxidative dehydrogenation reaction, and the like, or combinations thereof.
  • the reactor 200 can operate under non-isothermal conditions in the catalyst bed 30; e.g., a temperature profile within the catalyst bed 30 is non-uniform.
  • a process conducted with the catalyst bed 30 as disclosed herein can be characterized by a selectivity to the one or more reaction products that is increased when compared to a selectivity to the one or more reaction products of an otherwise similar process conducted with a fixed catalyst bed wherein the first intermediate bed cross sectional area and the second intermediate bed cross sectional area are not smaller than the bed inlet surface area, the bed outlet surface area, or both.
  • selectivity can be increased.
  • a temperature can increase in the direction of the flow through a reactor as a result of the reaction occurring to a higher extent as the reactants travel through the catalyst bed.
  • a catalyst cross sectional area can be decreased, which can lead to an increased by-pass flow through an annular space 34 formed between an outer surface of the catalyst bed 30 and an inner surface of a reactor wall 10.
  • the presence of the annular space 34 resulting from the configuration of the catalyst bed 30 as displayed in Figure 4 can result in a reduction of temperature increase, and therefore in a reduction of undesired by-products formation.
  • a catalyst cross sectional area can be increased to maximize the conversion of feed.
  • the increase in catalyst cross sectional area can ensure conversion of feed.
  • a catalyst cross sectional area can be increased again once reactant concentration has dropped sufficiently to avoid formation of by-products.
  • lengths of various zones of the catalyst bed can be modified to provide for a contact time needed for desired reactions.
  • greater feed concentrations and higher contact times tapering of catalyst cross sectional area can help reduce a reactant concentration through conversion, while reactants have lesser contact with catalyst (as compared to a higher catalyst loading/higher catalyst cross sectional area).
  • a catalyst cross sectional area can be increased again once reactant concentration has dropped sufficiently to avoid formation of by-products.
  • a process for producing syngas comprises reacting under non-adiabatic and near- isothermal conditions, via a CPO reaction, a reactant mixture in a continuous flow fixed-bed tubular reactor 101 to produce syngas, wherein the reactant mixture comprises hydrocarbons and oxygen, wherein the reactor 101 comprises a catalyst bed 20 disposed therein, wherein the catalyst bed 20 comprises a CPO catalyst, wherein a reactor wall inner surface and a catalyst bed outer surface define an annular space (24, 25) along at least a portion of a length of the catalyst bed, wherein the catalyst bed 20 is characterized by a prolate spheroidal shape, wherein the length of the catalyst bed 20 is greater than an inner reactor diameter; wherein the reactor 101 is characterized by a contact time of from about 0.001 milliseconds (ms) to about 5 ms, and wherein the syngas comprises hydrogen, carbon monoxide, carbon dioxide, water, and unreacted hydrocarbons.
  • the reactor 101 comprises a catalyst bed 20 disposed therein, wherein the catalyst
  • a process for producing syngas as disclosed herein can comprise reacting under non- adiabatic and near-isothermal conditions, via a MSR-CPO reaction, a reactant mixture in a continuous flow fixed-bed tubular reactor 101, 102, 103 to produce syngas; wherein the reactor 101, 102, 103 comprises a fixed CPO catalyst bed 20 disposed therein, wherein the fixed CPO catalyst bed 20 is characterized by a shape selected from the group consisting of a prolate spheroidal shape, an oblate spheroidal shape, a spherical shape, a shape of two truncated cones joined at their bases, and combinations thereof; wherein the reactant mixture comprises methane and oxygen; wherein the reactant mixture is characterized by a methane to oxygen (CH 4 /O 2 ) molar ratio of from about 1.6:1 to about 2.2:1; wherein the reactor 101, 102, 103 is characterized by a near-isother
  • a fixed-bed catalyst configuration and methods of using same as disclosed herein can advantageously display improvements in one or more catalyst bed characteristics when compared to an otherwise similar fixed-bed catalyst that is not characterized by a non-uniform cross section along the catalyst bed.
  • a catalyst bed for exothermic heterogeneous catalytic reactions such as catalyst bed 20, as disclosed herein, can advantageously have a configuration (e.g., shape) that can provide for near-isothermal conditions within the catalyst bed (e.g., an uniform temperature profile across the catalyst bed).
  • a catalyst bed for non-exothermic heterogeneous catalytic reactions and certain exothermic reactions where undesired by-products formation needs to be reduced can advantageously have a configuration (e.g., shape) that can provide for a decrease in temperature in some regions of the catalyst bed 30 (e.g., a non-uniform temperature profile across the catalyst bed), thereby reducing side reactions within the catalyst bed. Additional advantages of the fixed-bed catalyst configurations and methods of using same as disclosed herein can be apparent to one of skill in the art viewing this disclosure.
  • a first aspect which is a process comprising (a) feeding a reactant mixture to a continuous flow fixed-bed tubular reactor, wherein the reactor comprises a catalyst bed disposed therein, and wherein a reactor wall inner surface and a catalyst bed outer surface define an annular space along at least a portion of a length of the catalyst bed; (b) exothermically reacting the reactant mixture in the catalyst bed via a heterogeneous catalytic reaction to produce a product mixture, wherein the product mixture comprises one or more reaction products; and (c) recovering at least one reaction product from the product mixture; wherein the catalyst bed comprises a bed inlet, a bed outlet, a first intermediate bed zone, and a second intermediate bed zone; wherein the first intermediate bed zone and the second intermediate bed zone are disposed between the bed inlet and the bed outlet; wherein the second intermediate bed zone is downflow of the first intermediate bed zone; wherein the bed inlet is characterized by a bed inlet surface area; wherein the bed outlet is characterized by a bed outlet surface
  • a second aspect which is the process of the first aspect, wherein an increase in the first intermediate bed cross sectional area is continuous along the first intermediate bed zone or portion thereof in the direction of the flow through the reactor.
  • a third aspect which is the process of any one of the first and the second aspects, wherein an increase in the first intermediate bed cross sectional area is step-wise along the first intermediate bed zone or portion thereof in the direction of the flow through the reactor.
  • a fourth aspect which is the process of any one of the first through the third aspects, wherein a decrease in the second intermediate bed cross sectional area is continuous along the second intermediate bed zone or portion thereof in the direction of the flow through the reactor.
  • a fifth aspect which is the process of any one of the first through the fourth aspects, wherein a decrease in the second intermediate bed cross sectional area is step-wise along the second intermediate bed zone or portion thereof in the direction of the flow through the reactor.
  • a sixth aspect which is the process of any one of the first through the fifth aspects, wherein the catalyst bed further comprises a third intermediate bed zone; wherein the third intermediate bed zone is disposed between the first intermediate bed zone and the second intermediate bed zone; wherein the third intermediate bed zone is downflow of the first intermediate bed zone; wherein the third intermediate bed zone is upflow of the second intermediate bed zone; wherein the third intermediate bed zone is characterized by a third intermediate bed cross sectional area; wherein the third intermediate bed cross sectional area is substantially constant along the third intermediate bed zone; and wherein the third intermediate bed cross sectional area is greater than the first intermediate bed cross sectional area, the second intermediate bed cross sectional area, or both.
  • a seventh aspect which is the process of any one of the first through the sixth aspects, wherein the annular space is discontinuous.
  • An eighth aspect which is the process of any one of the first through the seventh aspects, wherein a reactor wall inner surface and an outer surface of the first intermediate bed zone define a first annular space; wherein a reactor wall inner surface and an outer surface of the second intermediate bed zone define a second annular space.
  • a ninth aspect which is the process of the eighth aspect, wherein the first annular space provides for staged addition of reactant mixture to the catalyst bed.
  • a tenth aspect which is the process of any one of the first through the ninth aspects, wherein the first annular space, the second annular space, or both comprise a radiation shield.
  • An eleventh aspect which is the process of any one of the first through the tenth aspects, wherein the first annular space, the second annular space, or both comprise one or more structural elements that are configured to provide for a catalyst bed configuration that is characterized by a non-uniform cross section along the catalyst bed.
  • a twelfth aspect which is the process of any one of the first through the eleventh aspects, wherein the catalyst bed comprises a structured catalyst that provides for a catalyst bed configuration that is characterized by a non-uniform cross section along the catalyst bed.
  • a thirteenth aspect which is the process of the twelfth aspect, wherein the structured catalyst comprises a metallic monolithic catalyst, a non-metallic monolithic catalyst, or both.
  • a fourteenth aspect which is the process of any one of the first through the thirteenth aspects, wherein the catalyst bed is characterized by a spherical shape.
  • a fifteenth aspect which is the process of any one of the first through the thirteenth aspects, wherein the catalyst bed is characterized by a prolate spheroidal shape, wherein a distance between the bed inlet and the bed outlet is greater than a diameter of a cross section of the first intermediate bed zone, a diameter of a cross section of the second intermediate bed zone, or both.
  • a sixteenth aspect which is the process of any one of the first through the thirteenth aspects, wherein the catalyst bed is characterized by an oblate spheroidal shape, wherein a distance between the bed inlet and the bed outlet is smaller than an inner reactor diameter.
  • a seventeenth aspect which is the process of any one of the first through the thirteenth aspects, wherein the first intermediate bed zone and/or the second intermediate bed zone are characterized by a truncated conical shape.
  • An eighteenth aspect which is the process of any one of the first through the seventeenth aspects, wherein the reactor operates under near-isothermal conditions in the catalyst bed.
  • a nineteenth aspect which is the process of any one of the first through the eighteenth aspects, wherein the heterogeneous catalytic reaction comprises an oxidation reaction, a catalytic partial oxidation (CPO) reaction, a "millisecond regime"- CPO (MSR-CPO) reaction, a hydrogenation reaction, an oxidative coupling reaction, an oxidative coupling of methane reaction, an oxidative dehydrogenation reaction, or combinations thereof.
  • CPO catalytic partial oxidation
  • MSR-CPO millisecond regime- CPO
  • a twentieth aspect which is the process of any one of the first through the nineteenth aspects, wherein the catalyst bed comprises a catalytic partial oxidation (CPO) catalyst.
  • CPO catalytic partial oxidation
  • a twenty-first aspect which is the process of any one of the first through the twentieth aspects, wherein the process is characterized by a conversion that is increased when compared to a conversion of an otherwise similar process conducted with a fixed catalyst bed wherein the first intermediate bed cross sectional area and the second intermediate bed cross sectional area are not greater than the bed inlet surface area, the bed outlet surface area, or both.
  • a twenty-second aspect which is the process of any one of the first through the twenty-first aspects, wherein the process is characterized by a selectivity to the one or more reaction products that is increased when compared to a selectivity to the one or more reaction products of an otherwise similar process conducted with a fixed catalyst bed wherein the first intermediate bed cross sectional area and the second intermediate bed cross sectional area are not greater than the bed inlet surface area, the bed outlet surface area, or both.
  • a twenty-third aspect which is the process of any one of the first through the twenty-second aspects, wherein the process is characterized by a bed inlet heat loss and/or a bed outlet heat loss that is decreased when compared to a bed inlet heat loss and/or a bed outlet heat loss of an otherwise similar process conducted with a fixed catalyst bed wherein the first intermediate bed cross sectional area and the second intermediate bed cross sectional area are not greater than the bed inlet surface area, the bed outlet surface area, or both.
  • a twenty-fourth aspect which is a reactor system comprising a continuous flow fixed-bed tubular reactor housing a catalyst bed; a reactant mixture flowing into the catalyst bed; a product mixture flowing out of the catalyst bed; wherein the reactor is configured to receive the reactant mixture and to produce the product mixture via an exothermic heterogeneous catalytic reaction in the catalyst bed; wherein the catalyst bed comprises a bed inlet, a bed outlet, a first intermediate bed zone, a second intermediate bed zone, and a third intermediate bed zone; wherein the first intermediate bed zone and the second intermediate bed zone are disposed between the bed inlet and the bed outlet; wherein the second intermediate bed zone is downflow of the first intermediate bed zone; wherein the third intermediate bed zone is disposed between the first intermediate bed zone and the second intermediate bed zone; wherein the third intermediate bed zone is downflow of the first intermediate bed zone; wherein the third intermediate bed zone is upflow of the second intermediate bed zone; wherein a reactor wall inner surface and an outer surface of the first intermediate bed zone define a first annul
  • a twenty-fifth aspect which is the reactor system of the twenty-fourth aspect, wherein the first annular space, the second annular space, or both comprise a radiation shield; and/or one or more structural elements that are configured to provide for a catalyst bed configuration that is characterized by a nonuniform cross section along the catalyst bed.
  • a twenty-sixth aspect which is the reactor system of any one of the twenty-fourth and the twenty-fifth aspects, wherein the catalyst bed comprises a structured catalyst that provides for a catalyst bed configuration that is characterized by a non-uniform cross section along the catalyst bed; and wherein the structured catalyst comprises a metallic monolithic catalyst, a non-metallic monolithic catalyst, or both.
  • a twenty-seventh aspect which is the reactor system of any one of the twenty-fourth through the twenty-sixth aspects, wherein a length of the first intermediate bed zone, a length of the second intermediate bed zone, a length of the third intermediate bed zone or combinations thereof are effective to provide for a desired contact time, a desired conversion, a desired selectivity, r combinations thereof.
  • a twenty-eighth aspect which is the reactor system of any one of the twenty-fourth through the twenty-seventh aspects, wherein the first annular space and/or the second annular space provide for a portion of the reactant mixture to by-pass a portion of the catalyst bed.
  • a twenty-ninth aspect which is the reactor system of any one of the twenty-fourth through the twenty-eighth aspects, wherein the first annular space and/or the second annular space are characterized by a variable annular cross sectional area.
  • a thirtieth aspect which is the reactor system of any one of the twenty-fourth through the twenty-ninth aspects, wherein the first annular space and/or the second annular space provide for controlling an extent of the heterogeneous catalytic reaction.
  • a thirty-first aspect which is a process comprising (a) feeding a reactant mixture to a continuous flow fixed-bed tubular reactor, wherein the reactor comprises a catalyst bed disposed therein, and wherein a reactor wall inner surface and a catalyst bed outer surface define an annular space; (b) non-exothermically or exothermically reacting the reactant mixture in the catalyst bed via a heterogeneous catalytic reaction to produce a product mixture, wherein the product mixture comprises one or more reaction products; and (c) recovering at least one reaction product from the product mixture; wherein the catalyst bed comprises a bed inlet, a bed outlet, a first intermediate bed zone, and a second intermediate bed zone; wherein the first intermediate bed zone and the second intermediate bed zone are disposed between the bed inlet and the bed outlet; wherein the second intermediate bed zone is downflow of the first intermediate bed zone; wherein the bed inlet is characterized by a bed inlet surface area; wherein the bed outlet is characterized by a bed outlet surface area; wherein the
  • a thirty-second aspect which is the process of the thirty-first aspect, wherein a decrease in the first intermediate bed cross sectional area is continuous along the first intermediate bed zone or portion thereof in the direction of the flow through the reactor.
  • a thirty-third aspect which is the process of any one of the thirty-first and the thirty-second aspects, wherein a decrease in the first intermediate bed cross sectional area is step-wise along the first intermediate bed zone or portion thereof in the direction of the flow through the reactor.
  • a thirty-fourth aspect which is the process of any one of the thirty-first through the thirty-third aspects, wherein an increase in the second intermediate bed cross sectional area is continuous along the second intermediate bed zone or portion thereof in the direction of the flow through the reactor.
  • a thirty-fifth aspect which is the process of any one of the thirty-first through the thirty-fourth aspects, wherein an increase in the second intermediate bed cross sectional area is step-wise along the second intermediate bed zone or portion thereof in the direction of the flow through the reactor.
  • a thirty-sixth aspect which is the process of any one of the thirty-first through the thirty-fifth aspects, wherein the reactor operates under non-isothermal conditions in the catalyst bed.
  • a thirty-seventh aspect which is the process of any one of the thirty-first through the thirty-sixth aspects, wherein the heterogeneous catalytic reaction comprises coke formation by dehydrogenation, an oxidation reaction, a catalytic partial oxidation (CPO) reaction, a hydrogenation reaction, cracking of products formed by coupling, further oxidation of CO to CO 2 by unreacted (3 ⁇ 4 or water formed in a reaction, or combinations thereof.
  • the heterogeneous catalytic reaction comprises coke formation by dehydrogenation, an oxidation reaction, a catalytic partial oxidation (CPO) reaction, a hydrogenation reaction, cracking of products formed by coupling, further oxidation of CO to CO 2 by unreacted (3 ⁇ 4 or water formed in a reaction, or combinations thereof.
  • a thirty-eighth aspect which is the process of any one of the thirty-first through the thirty- seventh aspects, wherein the annular space comprise one or more structural elements that are configured to provide for a catalyst bed configuration that is characterized by a non-uniform cross section along the catalyst bed.
  • a thirty-ninth aspect which is the process of any one of the thirty-first through the thirty-eighth aspects, wherein the process is characterized by a selectivity to the one or more reaction products that is increased when compared to a selectivity to the one or more reaction products of an otherwise similar process conducted with a fixed catalyst bed wherein the first intermediate bed cross sectional area and the second intermediate bed cross sectional area are not smaller than the bed inlet surface area, the bed outlet surface area, or both.
  • a fortieth aspect which is a reactor system comprising a continuous flow fixed-bed tubular reactor housing a catalyst bed; a reactant mixture flowing into the catalyst bed; a product mixture flowing out of the catalyst bed; wherein the reactor is configured to receive the reactant mixture and to produce the product mixture via a non-exothermic or exothermic heterogeneous catalytic reaction in the catalyst bed; wherein the catalyst bed comprises a bed inlet, a bed outlet, a first intermediate bed zone, and a second intermediate bed zone; wherein the first intermediate bed zone and the second intermediate bed zone are disposed between the bed inlet and the bed outlet; wherein the second intermediate bed zone is downflow of the first intermediate bed zone; wherein a reactor wall inner surface, an outer surface of the first intermediate bed zone, and an outer surface of the second intermediate bed zone define an annular space; wherein the bed inlet is characterized by a bed inlet surface area; wherein the bed outlet is characterized by a bed outlet surface area; wherein the first intermediate bed zone is characterized
  • a forty-first aspect which is the reactor system of the fortieth aspect, wherein the annular space comprises one or more structural elements that are configured to provide for a catalyst bed configuration that is characterized by a non-uniform cross section along the catalyst bed.
  • a forty-second aspect which is the reactor system of any one of the fortieth and the forty-first aspects, wherein the catalyst bed comprises a structured catalyst that provides for a catalyst bed configuration that is characterized by a non-uniform cross section along the catalyst bed; and wherein the structured catalyst comprises a metallic monolithic catalyst, a non-metallic monolithic catalyst, or both.
  • a forty-third aspect which is a process for producing syngas comprising reacting under non- adiabatic and near-isothermal conditions, via a catalytic partial oxidation (CPO) reaction, a reactant mixture in a continuous flow fixed-bed tubular reactor to produce syngas; wherein the reactant mixture comprises hydrocarbons and oxygen; wherein the reactor comprises a catalyst bed disposed therein; wherein the catalyst bed comprises a CPO catalyst; wherein a reactor wall inner surface and a catalyst bed outer surface define an annular space along at least a portion of a length of the catalyst bed; wherein the catalyst bed is characterized by a shape selected from the group consisting of a prolate spheroidal shape, an oblate spheroidal shape, a spherical shape, a shape of two truncated cones joined at their bases, and combinations thereof; wherein the reactor is characterized by a contact time of from about 0.001 milliseconds (ms) to about 5 ms; and

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Abstract

Un processus comprenant l'introduction d'un mélange réactif dans un réacteur tubulaire à lit fixe à écoulement continu, comprenant un lit de catalyseur disposé à l'intérieur, une surface interne de paroi de réacteur et une surface externe de lit de catalyseur définissant un espace annulaire; faire réagir de manière exothermique un mélange de réactifs dans un lit de catalyseur par l'intermédiaire d'une réaction catalytique hétérogène pour produire un mélange de produits comprenant des produits de réaction; et récupérer au moins un produit de réaction à partir du mélange de produits; le lit de catalyseur comprenant une entrée et une sortie de lit, une première zone de lit intermédiaire, et une seconde zone de lit intermédiaire descendant de la première zone de lit intermédiaire; des première et seconde zones de lit intermédiaire étant disposées entre l'entrée et la sortie de lit; la première zone de section transversale de lit intermédiaire augmentant dans la direction d'écoulement; la seconde surface de section transversale de lit intermédiaire diminuant dans la direction d'écoulement; et les première et seconde zones de section transversale de lit intermédiaire étant supérieures à la surface d'entrée de lit et/ou à la surface de sortie de lit.
PCT/IB2018/054475 2017-06-21 2018-06-18 Conceptions de réacteur améliorées pour réactions catalytiques hétérogènes Ceased WO2018234975A1 (fr)

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US20030219903A1 (en) * 2002-05-21 2003-11-27 Yong Wang Reactors having varying cross-section, methods of making same, and methods of conducting reactions with varying local contact time
US20060029539A1 (en) * 2004-08-06 2006-02-09 Conocophillips Company Synthesis gas process comprising partial oxidation using controlled and optimized temperature profile
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WO2016075651A1 (fr) * 2014-11-14 2016-05-19 Sabic Global Technologies B.V. Réacteur à lit fixe et procédés associés

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US20030068261A1 (en) * 2001-08-02 2003-04-10 Hassan Taheri Flow reactors for chemical conversions with heterogeneous catalysts
US20030219903A1 (en) * 2002-05-21 2003-11-27 Yong Wang Reactors having varying cross-section, methods of making same, and methods of conducting reactions with varying local contact time
US20060029539A1 (en) * 2004-08-06 2006-02-09 Conocophillips Company Synthesis gas process comprising partial oxidation using controlled and optimized temperature profile
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116328749A (zh) * 2022-06-13 2023-06-27 中晶城康资源再生利用技术有限公司 一种改性镁铝水滑石催化剂及其制备方法和应用

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