Reactors and methods for processes involving partial oxidation reactions
First Claim
1. A reactor suitable for conducting a partial oxidative reaction, wherein the reactor comprises a vessel comprising a process channel and two or more composite catalyst structures in the form of a stack,wherein each composite catalyst structure comprises a catalyst layer, wherein the catalyst layer comprises a porous substrate and a catalyst,wherein the porous substrate comprises sintered microfibrous media comprising a metal or metal alloy, non-sintered metal mesh, sintered metal mesh, metal honeycomb, metal monolith, ceramics, or a combination thereof,wherein at least a portion of at least one of the two or more composite catalyst structures comprises a layer comprising a porous heat transfer structure configured to quench free radicals and prevent explosions or propagation of a fire during the partial oxidative reaction, andwherein the porous heat transfer structure comprises a heat spreader layer that does not contain the catalyst.
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Abstract
Described herein are improved chemical reactors for carrying out partial oxidation reactions. The chemical reactor permits the use of levels of oxygen above the lower explosion limit (LEL) typically used in partial oxidation reactions, which increases both volumetric reactivity and conversion per pass, resulting in reduced separation and reactant recycle costs. Also described are methods of using the reactors.
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Citations
25 Claims
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1. A reactor suitable for conducting a partial oxidative reaction, wherein the reactor comprises a vessel comprising a process channel and two or more composite catalyst structures in the form of a stack,
wherein each composite catalyst structure comprises a catalyst layer, wherein the catalyst layer comprises a porous substrate and a catalyst, wherein the porous substrate comprises sintered microfibrous media comprising a metal or metal alloy, non-sintered metal mesh, sintered metal mesh, metal honeycomb, metal monolith, ceramics, or a combination thereof, wherein at least a portion of at least one of the two or more composite catalyst structures comprises a layer comprising a porous heat transfer structure configured to quench free radicals and prevent explosions or propagation of a fire during the partial oxidative reaction, and wherein the porous heat transfer structure comprises a heat spreader layer that does not contain the catalyst.
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18. A reactor suitable for conducting a partial oxidative reaction, wherein the reactor comprises a vessel comprising two or more composite catalyst structures in the form of a stack, wherein at least one of the two or more composite catalyst structures comprises:
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(i) a catalyst layer comprising (a) a catalyst, and (b) sintered microfibrous media, non-sintered metal mesh, sintered metal mesh, metal honeycomb, porous metal monolith, ceramics, or a combination thereof, and (ii) a barrier layer comprising a material with pores or interstitial spaces of a sufficient size to prevent the catalyst from migrating out of the catalyst layer, or (iii) a heat spreader layer configured to dissipate heat, or (iv) both (ii) and (iii), wherein the barrier layer, the heat spreader layer, or both, comprise a metal or metal alloy, and wherein the catalyst is not present in the heat spreader layer.
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Specification