Chemical reactor with enhanced heat exchange

• US 20040141893A1
• Filed: 01/21/2003
• Published: 07/22/2004
• Est. Priority Date: 01/21/2003
• Status: Abandoned Application

• Current Assignee: Mesoscopic Devices Incorporated
• Original Assignee: Mesoscopic Devices Incorporated
• Inventors: Martin, Jerry L.
• Application Number:
  US10/348,102
• Publication Number:
  US 20040141893A1
• Time in Patent Office: Days
• US Class Current: 422/198
• CPC Class Codes: B01J 12/007 in the presence of catalytically active bodies, e.g. porous plates
• CPC Class Codes: B01J 19/249 Plate-type reactors
• CPC Class Codes: B01J 2219/00096 Plates
• CPC Class Codes: B01J 2219/2453 Plates arranged in parallel
• CPC Class Codes: B01J 2219/2454 Plates arranged concentrically
• CPC Class Codes: B01J 2219/2458 Flat plates, i.e. plates which are not corrugated or otherwise structured, e.g. plates with cylindrical shape
• CPC Class Codes: B01J 2219/2465 Two reactions in indirect heat exchange with each other
• CPC Class Codes: B01J 2219/2467 Additional heat exchange means, e.g. electric resistance heaters, coils
• CPC Class Codes: B01J 2219/2479 Catalysts coated on the surface of plates or inserts
• CPC Class Codes: B01J 2219/2485 Metals or alloys
• CPC Class Codes: B01J 23/42 Platinum
• CPC Class Codes: C01B 2203/0216 containing a non-catalytic steam reforming step
• CPC Class Codes: C01B 2203/0811 by combustion of fuel
• CPC Class Codes: C01B 2203/0822 the fuel containing hydrogen
• CPC Class Codes: C01B 2203/0827 at least part of the fuel being a recycle stream
• CPC Class Codes: C01B 3/384 the catalyst being continuously externally heated
• CPC Class Codes: F28D 9/04 the conduits being formed by spirally-wound plates or laminae
• CPC Class Codes: F28F 13/003 by using permeable mass, perforated or porous materials F28F13/18 takes precedence
• CPC Class Codes: F28F 3/086 having one or more openings therein forming tubular heat-exchange passages
• CPC Class Codes: Y02P 20/10 Process efficiency
• CPC Class Codes: Y02P 20/52 : using catalysts, e.g. selective catalysts

Abstract

A reactor, system and method are described for performing a chemical reaction characterized by a heat of reaction. The reactor includes a first thermally conductive arrangement defining at least one catalytically active flow passage for conducting a fluid at least generally in a predetermined direction while catalytically activating the chemical reaction in a way which produces the heat of reaction. The heat of reaction conducts through the first thermally conductive arrangement in a direction at least generally parallel with the predetermined direction. A second thermally conductive arrangement is in thermal communication with the first thermally conductive arrangement and is configured for transferring the heat of reaction to an external process and for redirecting the fluid received from the first thermally conductive arrangement to a different direction. The first and second arrangements may be integrally formed using a laminated structure. A system may include a pair of thermally coupled such reactors.

Claims

27. In producing an assembly for use in performing a chemical reaction having a heat of reaction, a method comprising the steps of:

defining at least one portion of a first thermally conductive means with at least one flow passage for conducting a fluid at least generally in a predetermined direction while catalytically activating said chemical reaction with said fluid in a way which produces said heat of reaction; and

arranging second thermally conductive means in thermal communication with said first thermally conductive means for conducting said heat of reaction through said first thermally conductive means in a heat transfer direction that is at least generally parallel with said predetermined direction and for redirecting the fluid received from said first thermally conductive means to a different direction as compared to said predetermined direction.

28. The method of claim 27 including the step of defining a plurality of said flow passages, each of which is catalytically active in said first thermally conductive means, that are at least generally parallel for conducting said fluid in said predetermined direction.

29. The method of claim 27 including the step of defining said catalytically active flow passage using a coiled strip in a way which provides a channel in which said fluid flows in said predetermined direction, thereby producing said heat of reaction.

30. The method of claim 27 including the step of defining a plurality of said catalytically active flow passages using a porous material in a way which provides a plurality of pores through which said fluid flows and a substantial portion of said heat of reaction conducts through the porous material.

31. The method of claim 30 wherein said porous material is selected as a catalytically active material.

32. The method of claim 30 including the step of treating said porous material with a catalytically active material.

33. The method of claim 27 including the step of forming said first thermally conductive means entirely from a catalytic material, serving to catalytically activate said heat of reaction and for defining the first passage arrangement.

34. The method of claim 27 including the step of defining at least said catalytically active flow passage of said first thermally conductive means using an interior wall arrangement having a surface area and said surface area supports a catalytic material for catalytically activating the flow passage.

35. The method of claim 27 wherein at least said catalytically active flow passage of said first thermally conductive means is defined by an interior wall arrangement forming an interior volume and including the step of capturing a catalytic material in said interior volume within said interior wall arrangement.

36. The method of claim 27 including the step of configuring said second thermally conductive means for providing an at least approximately constant thermal flux per unit area therethrough in said direction that is at least generally parallel to the predetermined direction.

37. The method of claim 27 including the steps of defining a plurality of said catalytically active flow passages using an interior wall arrangement having a surface area and sizing said surface area based on certain process characteristics of said chemical reaction including said heat of reaction.

38. The method of claim 37 wherein said each flow passage of said first thermally conductive means includes a length at least generally along said predetermined direction such that the surface area is sized based, at least in part, on said length.

39. The method of claim 37 wherein said first thermally conductive means includes a peripheral outline such that said surface area is sized based, at least in part, on modifying the peripheral outline.

40. The method of claim 27 wherein said first thermally conductive means includes a peripheral outline and an interior wall arrangement forming a wetted perimeter, and including the step of sizing said peripheral outline to modify said wetted perimeter.

41. The method of claim 27 including the step of integrally forming said first thermally conductive means and said second thermally conductive means as portions of an overall laminated thermally conductive body.

42. The method of claim 41 wherein the step of integrally forming the overall laminated thermally conductive body includes the steps of stacking an alternating series of first and second plate members, each of which plate members is integrally formed, stacked in thermal communication such that the first and second plate members cooperate to define

a plurality of said catalytically active flow passages formed between adjacent ones of the first plate members, in said alternating series, which are held in a spaced apart, confronting relationship by one of the second plate members, said passages having an outermost passage opening for use in forming a first external flow connection with said assembly and having an innermost, opposing passage end that is bounded by the second plate member,

at least one exit channel extending transversely through said alternating series of plate members in flow communication with said passage ends and extending to an outermost, end one of the plate members to define an external channel opening in the end one of the plate members for use in forming a second external flow connection with said assembly, and

a laminated thermal header arrangement formed by adjacent end portions of the first and second plate members which at least partially serve to define said exit channel and which further cooperate to define an external thermal interface surface of said assembly for providing external thermal communication.

43. The method of claim 27 including the step of integrally forming said first thermally conductive means and said second thermally conductive means.

44. The method of claim 27 including the steps of separately forming said first thermally conductive means and said second thermally conductive means and interfacing said first thermally conductive means and said second thermally conductive means in a way which provides said thermal communication.

45. In producing a system for thermally coupling an exothermic reaction with an endothermic reaction, a method comprising the steps of:

forming a first assembly according to claim 27 for supporting said exothermic reaction having a first heat of reaction;

forming a second assembly according to claim 27 for supporting said endothermic reaction having a second heat of reaction; and

arranging said second thermally conductive means of said second assembly in thermal communication with said second thermally conductive means of said first assembly for thermally coupling said first heat of reaction with said second heat of reaction.

46. A compact chemical reactor, comprising:

thermally conductive means including a first portion for defining one or more catalytically active channels through which a reaction fluid flows and which cooperate to at least generally define a flow direction of said reaction fluid therethrough, thereby producing a heat of reaction, and a second portion for defining at least one exit channel in fluid communication with said catalytically active channels and for further defining a heat transfer surface, in thermal communication with said first portion defining the catalytically active channels, in a way which serves to redirect flow of the reaction fluid from the catalytically active channels into the exit channel such that a direction in which the heat of reaction conducts through said first portion is at least generally parallel to said flow direction and a substantial portion of said heat of reaction passes through said heat transfer surface.

47. The compact chemical reactor of claim 46 wherein a direction of fluid flow within the catalytic reaction path is at least generally normal to the exit portion of the fluid path.

48. The compact chemical reactor of claim 46 wherein said first portion includes a porous material defining a plurality of pores such that said reaction fluid flows through the pores and said heat of reaction conducts primarily within the pore defining structure of the porous material.

49. The compact chemical reactor of claim 46 wherein said first portion is a catalytically active material.

50. The compact chemical reactor of claim 46 wherein said catalytically active channels are defined by an interior surface that is treated with a catalytically active material.

51. The compact chemical reactor of claim 46 wherein said first portion includes an interior wall arrangement forming an interior volume for defining said catalytically active channels and said interior volume contains a catalytic material that is captured within said interior wall arrangement.

52. The compact chemical reactor of claim 46 wherein said first portion includes a coiled strip for defining at least one of said channels in which said reaction fluid flows.

53. The compact chemical reactor of claim 46 wherein said first portion and said second portion of the thermally conductive means are separately formed and interfaced in a way which provides thermal communication therebetween.

54. A method for producing a compact chemical reactor within an overall thermally conductive arrangement, said method comprising the steps of:

forming thermally conductive means including a first portion for defining one or more catalytically active channels through which a reaction fluid is to flow and which channels cooperate to at least generally define a flow direction of said reaction fluid therethrough, thereby producing a heat of reaction and a second portion for defining at least one exit channel in fluid communication with said plurality of catalytically active channels, and said second portion further defining a heat transfer surface such that said flow direction is at least generally parallel with a direction in which the heat of reaction conducts through said first portion and at least a substantial portion of the heat of reaction passes through said heat transfer surface and external to the compact chemical reactor.

55. The method of claim 54 including the step of integrally forming said first portion and said second portion of the thermally conductive means as parts of an overall laminated thermally conductive body.

56. The method of claim 54 including the step of integrally forming said first portion and said second portion of the thermally conductive means.

57. The method of claim 54 including the steps of separately forming said first portion and said second portion of the thermally conductive means and thermally interfacing the first and second portions.

58. The method of claim 54 including the step of defining a plurality of said catalytically active flow channels using a porous material defining a plurality of pores through which said fluid flows and the said heat of reaction conducts primarily through said porous material.

59. The method of claim 54 wherein said first portion is selected as a catalytically active material.

60. The method of claim 54 wherein said catalytically active channels are defined by an interior surface and including the step of treating said interior surface with a catalytically active material.

61. The method of claim 54 wherein said first portion includes an interior wall arrangement forming an interior volume for defining said catalytically active channels and including the step of capturing a catalytic material within said interior volume using said interior wall arrangement.

62. The method of claim 54 including the step of using a coiled strip in a way which provides at least one of said catalytically active channels in which said fluid flows in said predetermined direction, thereby producing said heat of reaction.

63. A method for transferring heat responsive to a chemical reaction in a compact chemical reactor within an overall thermally conductive structure, said method comprising the steps of:

forming a plurality of catalytically active channels, as a first portion of said overall thermally conductive structure, through which a reaction fluid is to flow, thereby producing a heat of reaction;

defining at least one exit channel in fluid communication with said plurality of catalytically active channels; and

configuring a heat transfer surface, as a second portion of said overall thermally conductive means, for redirecting flow of the reaction fluid from the catalytically active channels across the heat transfer surface and, thereafter, into the exit channel such that at least a substantial portion of the heat of reaction is conducted along said first portion of the thermally conductive structure and through said heat transfer surface.

1. An assembly for use in performing a chemical reaction that is characterized by a heat of reaction, said assembly comprising:

first thermally conductive means defining at least one catalytically active flow passage for conducting a fluid at least generally in a predetermined direction while catalytically activating said chemical reaction with said fluid in a way which produces said heat of reaction and said heat of reaction conducts primarily through said first thermally conductive means in a direction at least generally parallel with said predetermined direction; and

second thermally conductive means in thermal communication with said first thermally conductive means and configured for transferring said heat of reaction to an external process and for redirecting the fluid received from said first thermally conductive means to a different direction as compared to said predetermined direction.

2. The assembly of claim 1 wherein said first thermally conductive means defines a plurality of said catalytically active flow passages that are at least generally parallel for conducting said fluid in said predetermined direction.

3. The assembly of claim 1 wherein said first thermally conductive means is formed using a coiled strip in a way which provides a channel in which said fluid flows in said predetermined direction, thereby producing said heat of reaction.

4. The assembly of claim 1 wherein said first thermally conductive means is formed using a porous material having a plurality of pores through which said fluid flows and a substantial portion of said heat of reaction conducts through said porous material.

5. The assembly of claim 4 wherein said porous material is catalytically active.

6. The assembly of claim 4 wherein said porous material is treated with a catalytically active material.

7. The assembly of claim 1 wherein at least said first thermally conductive means is formed entirely from a catalytic material serving to catalytically activate said heat of reaction and for defining said flow passage.

8. The assembly of claim 1 wherein at least said catalytically active flow passage of said first thermally conductive means is defined by an interior wall arrangement having a surface area and said surface area supports a catalytic material for catalytically activating the flow passage.

9. The assembly of claim 1 wherein at least said catalytically active flow passage of said first thermally conductive means is defined by an interior wall arrangement forming an interior volume and said interior volume contains a catalytic material that is captured within said interior wall arrangement.

10. The assembly of claim 1 wherein said second thermally conductive means is configured for providing an at least approximately constant thermal flux per unit area therethrough in said direction that is at least generally parallel to the predetermined direction.

11. The assembly of claim 1 wherein said first thermally conductive means defines a plurality of said catalytically active flow passages that is formed by an interior wall arrangement having a surface area, and said surface area is sized based on certain process characteristics of said chemical reaction including said heat of reaction.

12. The assembly of claim 11 wherein said each flow passage of said first thermally conductive means includes a length at least generally along said predetermined direction such that the surface area is sized based, at least in part, on said length.

13. The assembly of claim 11 wherein said first thermally conductive means includes a peripheral outline such that said surface area is sized based, at least in part, on modifying the peripheral outline.

14. The assembly of claim 1 wherein said first thermally conductive means includes a peripheral outline and an interior wall arrangement forming a wetted perimeter, and said peripheral outline is sized to modify said wetted perimeter.

15. The assembly of claim 1 wherein said first thermally conductive means and said second thermally conductive means are integrally formed as portions of an overall laminated thermally conductive body.

16. The assembly of claim 15 wherein said overall laminated thermally conductive body includes an alternating series of first and second plate members, each of which plate members is integrally formed, stacked in thermal communication such that the first and second plate members cooperate to define

a plurality of said catalytically active flow passages formed between adjacent ones of the first plate members, in said alternating series, which are held in a spaced apart, confronting relationship by one of the second plate members, said passages having an outermost passage opening for use in forming a first external flow connection with said assembly and having an innermost, opposing passage end that is bounded by the second plate member,

at least one exit channel extending transversely through said alternating series of plate members in flow communication with said passage ends and extending to an outermost, end one of the plate members to define an external channel opening in the end one of the plate members for use in forming a second external flow connection with said assembly, and

a laminated thermal header arrangement formed by adjacent end portions of the first and second plate members which at least partially serve to define said exit channel and which further cooperate to define an external thermal interface surface of said assembly for providing external thermal communication.

17. The assembly of claim 16 configured for defining a plurality of said exit channels in a spaced apart, at least generally parallel relationship.

18. The assembly of claim 16 wherein said exit channel includes a length extending through a an overall stacked thickness of the alternating series of said plate members and terminating in opposing first and second ones of outermost channel ends having a first and a second external channel opening, respectively, and said assembly further includes means for sealing a selected one of the first and second opposing channel openings.

19. The assembly of claim 16 wherein said sealing means includes a sealing plate that is attached to an end one of said first and second plate members.

20. The assembly of claim 16 wherein said exit channel is at least generally normal to each of said first and second plate members.

21. The assembly of claim 16 wherein the predetermined direction of fluid flow through said passages is at least generally parallel to heat flow through said first and second plate members.

22. The assembly of claim 16 wherein an additional pair of plate members including an additional first plate member and an additional second plate member, as part of said layered configuration, extend the alternating series of plate members to define an additional passage including an additional outermost passage opening for use in forming said first external flow connection with said assembly and an additional innermost, opposing passage end that is bounded by the additional second plate member and further cooperatively extending said exit channel transversely through the additional first and additional second plate members, in flow communication with the catalytically active passages and with the additional passage, and said additional second plate member serving as the end plate member so as to define said external channel opening and said additional first and second plate members including additional adjacent end portions which at least partially serve to define said exit channel and which further cooperate to extend said external thermal interface surface.

23. The assembly of claim 22 including one or more further additional pairs of the first and second integrally formed plate members, within said layered configuration, each of which further additional pairs cooperates in the series of plate members to define a further additional passage including a further additional outermost passage opening for use in forming said first external connection with said assembly and a further additional innermost, opposing end bounded, at least in part, by the second plate member of each further additional pair of first and second plate members and further cooperatively extending said exit channel transversely through the further additional first and second plate members in flow communication with each further additional passage.

24. The assembly of claim 1 wherein said first thermally conductive means and said second thermally conductive means are integrally formed.

25. The assembly of claim 1 wherein said first thermally conductive means and said second thermally conductive means are separately formed and thermally interfaced in a way which provides said thermal communication.

26. A system for thermally coupling an exothermic reaction with an endothermic reaction, said system comprising:

a first assembly according to claim 1 for supporting said exothermic reaction having a first heat of reaction; and

a second assembly according to claim 1 for supporting said endothermic reaction and having a second heat of reaction, and said second thermally conductive means of said second assembly arranged in thermal communication with said second thermally conductive means of said first assembly for thermally coupling said first heat of reaction with said second heat of reaction.

64. The method of claim 63 wherein said plurality of catalytically active channels define a flow direction of said fluid that is at least generally parallel with conduction of said heat of reaction through said first portion of said overall thermally conductive structure.

90. The system of claim 88 wherein said first thermally conductive means and said second thermally conductive means include a first peripheral outline and a second peripheral outline, respectively, such that said first surface area and the second surface area are sized based, at least in part, on modifying the first peripheral outline and the second peripheral outline.

91. The system of claim 64 further comprising:

thermal coupling means for providing said thermal communication and to thermally couple said heat of reaction between the first thermal interface member and the second thermal interface member in a way which establishes a selected value of thermal conductance between the first thermally conductive means and the second thermally conductive means that permits said first process to operate at a first preferred temperature, at said first internal surface of the first thermal interface member, and that permits said second process to operate at a second preferred temperature, at said second internal interface of the second thermal interface member.

65. A system for transferring a heat of reaction between first and second processes that are performed within the system, said system comprising:

first thermally conductive means for executing said first process and configured for receiving a first flow of a first fluid through a first passage arrangement such that an overall flow of the first fluid includes a first directional orientation that is directed toward a first internal surface of a first thermal interface member, formed by the first thermally conductive means, and said first thermally conductive means is further configured for directing said first fluid outwardly therefrom and away from said first directional orientation across said first internal surface;

second thermally conductive means for executing said second process and configured for receiving a second flow of a second fluid through a second passage arrangement such that the overall flow of the second fluid includes a second directional orientation that is directed toward a second internal surface of a second thermal interface member, formed by the second thermally conductive means, and said second thermally conductive means is further configured for directing said second fluid away from said second directional orientation across said second internal surface, said second thermal interface member being arranged in thermal communication with said first thermal interface member such that said first and second processes are thermally coupled between said first and second thermal interface members; and

at least one of said first and second thermally conductive means including a configuration for catalytically activating at least a selected one of the first passage arrangement and the second passage arrangement so as to produce said heat of reaction for thermal coupling through said first and second thermal interface members.

66. The system of claim 65 wherein said heat of reaction conducts primarily along said first thermally conductive means in a direction at least generally parallel with said first directional orientation.

67. The system of claim 65 wherein said heat of reaction conducts primarily along said second thermally conductive means in a direction at least generally parallel with said second directional orientation.

68. The system of claim 65 wherein said first passage arrangement defines a first plurality of channels that are at least generally parallel and said second passage arrangement defines a second plurality of channels that are at least generally parallel.

69. The system of claim 65 wherein said catalytic reaction is endothermic.

70. The system of claim 65 wherein said catalytic reaction is exothermic.

71. The system of claim 69 wherein said catalytic reaction is steam reforming.

72. The system of claim 71 wherein hydrogen gas is produced by steam reforming.

73. The system of claim 71 wherein the second passage arrangement of said second thermally conductive means includes an additional catalyst such that the second thermally conductive means activates a catalytic combustion of said second fluid to produce said heat of reaction traveling from said second thermally conductive means to said first thermally conductive means for use in said steam reforming.

74. The system of claim 65 wherein said first thermally conductive means includes said configuration for catalytically activating an exothermic reaction with said first fluid and said second thermally conductive means includes an additional configuration for catalytically activating an endothermic reaction with said second fluid.

75. The system of claim 65 wherein said heat of reaction is thermally balanced by a phase change of said second fluid in said second thermally conductive means.

76. The system of claim 65 wherein said first and second thermal interface members support said first and second internal surfaces in a spaced apart, at least approximately parallel relationship.

77. The system of claim 65 wherein said first and second thermally conductive means are integrally formed as portions of an overall thermally conductive body.

78. The system of claim 65 wherein said first and second thermally conductive means are individually formed and thermally connected at said first and second thermal interface members.

79. The system of claim 65 wherein at least said first passage arrangement of the first thermally conductive arrangement includes a porous material defining a plurality of pores through which said fluid flows and the heat of reaction conducts primarily through said porous material.

80. The system of claim 65 wherein said first thermally conductive means is a catalytically active material.

81. The system of claim 65 wherein said configuration for activating at least one of the first passage arrangement and the second passage arrangement includes a catalytically active material applied to one or more inner surfaces defining at least one of the first and second passage arrangement.

82. The system of claim 65 wherein said first passage arrangement and said second passage arrangement define an interior volume and wherein said configuration for catalytically activating at least one of the first passage arrangement and the second passage arrangement includes a catalytic material that is captured within the catalytically activated ones of the first and second passage arrangements.

83. The system of claim 79 wherein said second passage arrangement of said second thermally conductive means is defined by an interior plate arrangement forming a plurality of at least generally parallel channels along said second directional orientation towards said second internal surface.

84. The system of claim 65 wherein at least said first thermally conductive means is formed entirely from a catalytic material serving as said configuration for catalytically activating and for defining the first passage arrangement.

85. The system of claim 65 wherein at least said first passage arrangement of said first thermally conductive means is defined by an interior wall arrangement having a surface area and said surface area supports a catalytic material for catalytically activating the first passage.

86. The system of claim 65 wherein at least said first passage arrangement of said first thermally conductive means is defined by an interior wall arrangement forming an interior volume and said interior volume contains a catalytic material that is captured within said interior wall arrangement.

87. The system of claim 65 wherein said first and second thermally conductive means are configured for providing an at least approximately constant thermal flux per unit area through said first and second thermal interface members.

88. The system of claim 65 wherein said first passage arrangement of the first thermally conductive means is formed by a first interior wall arrangement defining a first plurality of at least generally parallel channels having a first surface area and said second passage arrangement of the second thermally conductive means is formed by a second interior wall arrangement defining a second plurality of at least generally parallel channels having a second surface area and said first and second surface areas are sized based on certain process characteristics of said first and second processes along with said heat of reaction.

89. The system of claim 88 wherein said first and second channels of said first and second thermally conductive means include a first length at least generally along said first directional orientation and a second length at least generally along said second directional orientation, respectively, such that the first surface area and the second surface area are sized based, at least in part, on said first length and said second length.

90-1. The system of claim 64 wherein said first thermally conductive means and said second thermally conductive means include a first peripheral outline and a second peripheral outline, respectively, and said configuration for catalytically activating at least a selected one of the first passage arrangement and the second passage arrangement forms a wetted perimeter such that the peripheral outline of the selected passage arrangement is sized to modify the wetted perimeter.