Trifluid reactor
First Claim
1. A reactor for reacting at least a first fluid comprising a first reactant and a second fluid comprising a second reactant, and mixing a diluent fluid with one or more portions of first fluid, second fluid and products of their reaction to form a reaction product, the reactor comprising:
- a duct having an axial direction and a first and second transverse directions mutually distinct from the axial direction, the first and second transverse directions defining a plane through an axial location, with the area of the plane within the inner surface of the duct defining a cross-sectional area of the duct at the axial location;
a reactant distribution portion comprising at least one reactant tubular portion having an inner surface and an outer surface, the inner surface defining a first flow path for the first fluid, and having a plurality of reactant distribution orifices extending from the inner surface to the outer surface, the plurality of reactant distribution orifices having a density distribution being the locally averaged spatial density of orifices per duct cross-sectional area, and having a size distribution, the distributions being with respect to at least one of the transverse directions;
a diluent distribution portion comprising at least one diluent tubular portion having an inner surface and an outer surface, the inner surface defining a first diluent flow path for the diluent, and a plurality of diluent orifices extending from the inner surface to the outer surface of the diluent tubular portion, the plurality of diluent orifices having a density and a size distribution, the distributions being with respect to at least one of the transverse directions;
a reactant delivery system for supplying the first fluid to the reactant distribution portion;
a second fluid delivery system for supplying at least a portion of the second fluid to the duct, wherein the duct defines a second flow path for the second fluid;
a diluent delivery system for supplying at least a portion of diluent to the diluent distribution portion;
a controller for controlling the delivery of the first fluid, the second fluid and the diluent fluid to the reactor; and
wherein the density and size distribution, with respect to at least one of the transverse directions, of the diluent orifices and of the reactant orifices are configured such that the distribution of at least one of the composition, temperature, pressure and velocity of the reaction product, is controlled in the at least one transverse direction in a cross section of the duct near the reactor exit, taken along a direction transverse to the duct axis.
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Accused Products
Abstract
A thermally diluted exothermic reactor system is comprised of numerous orifices distributed within a combustor by distributed perforated contactor tubes or ducts. The perforated contactors deliver and mix diluent fluid and one or more reactant fluids with an oxidant fluid. Numerous micro-jets about the perforated tubes deliver, mix and control the composition of reactant fluid, oxidant fluid and diluent fluid. The reactor controls one or more of composition profiles, composition ratio profiles and temperature profiles in one or more of the axial direction and one or two transverse directions, reduces temperature gradients and improves power, efficiency and emissions.
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Citations
84 Claims
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1. A reactor for reacting at least a first fluid comprising a first reactant and a second fluid comprising a second reactant, and mixing a diluent fluid with one or more portions of first fluid, second fluid and products of their reaction to form a reaction product, the reactor comprising:
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a duct having an axial direction and a first and second transverse directions mutually distinct from the axial direction, the first and second transverse directions defining a plane through an axial location, with the area of the plane within the inner surface of the duct defining a cross-sectional area of the duct at the axial location;
a reactant distribution portion comprising at least one reactant tubular portion having an inner surface and an outer surface, the inner surface defining a first flow path for the first fluid, and having a plurality of reactant distribution orifices extending from the inner surface to the outer surface, the plurality of reactant distribution orifices having a density distribution being the locally averaged spatial density of orifices per duct cross-sectional area, and having a size distribution, the distributions being with respect to at least one of the transverse directions;
a diluent distribution portion comprising at least one diluent tubular portion having an inner surface and an outer surface, the inner surface defining a first diluent flow path for the diluent, and a plurality of diluent orifices extending from the inner surface to the outer surface of the diluent tubular portion, the plurality of diluent orifices having a density and a size distribution, the distributions being with respect to at least one of the transverse directions;
a reactant delivery system for supplying the first fluid to the reactant distribution portion;
a second fluid delivery system for supplying at least a portion of the second fluid to the duct, wherein the duct defines a second flow path for the second fluid;
a diluent delivery system for supplying at least a portion of diluent to the diluent distribution portion;
a controller for controlling the delivery of the first fluid, the second fluid and the diluent fluid to the reactor; and
wherein the density and size distribution, with respect to at least one of the transverse directions, of the diluent orifices and of the reactant orifices are configured such that the distribution of at least one of the composition, temperature, pressure and velocity of the reaction product, is controlled in the at least one transverse direction in a cross section of the duct near the reactor exit, taken along a direction transverse to the duct axis. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39)
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40. A method of reacting a first reactant with a second reactant and mixing a diluent fluid with at least one of the first and second reactants and a reaction product to form a product fluid;
- the method comprising;
providing a reactor;
the reactor having an axial direction and a first and second transverse directions mutually distinct from the axial direction, the first and second transverse directions defining a plane through an axial location, with the area of the plane constrained within an inner surface of the reaction defining a cross-sectional area of the reaction at the axial location;
providing a first reactant delivery system to deliver a first reactant fluid comprising the first reactant to the reactor;
providing a second reactant delivery system to deliver a second reactant fluid comprising the second reactant to the reactor;
providing a diluent delivery system to deliver the diluent fluid to the reactor;
controlling the spatial delivery of the second reactant fluid into the reactor in at least one of the transverse directions;
controlling the spatial delivery of the diluent fluid into the reactor in at least one of the transverse directions; and
wherein controlling the at least one spatial distribution of the second reactant fluid and the diluent in at least one of the transverse directions controls at least one of the composition, temperature, pressure and velocity of the reaction product, in at least one transverse direction near an exit of the reactor taken in a cross section of the reactor. - View Dependent Claims (41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 78, 79, 80)
- the method comprising;
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63. A fluid delivery system comprising:
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a pump comprising at least one pump member that moves in a reciprocal or rotational manner to deliver a fluid with a flow delivery distribution per pump cycle, and operable of moving through a plurality of fluid delivery cycles;
a motor operationally coupled to the at least one pump member to produce said reciprocal or rotational movement; and
a controller operationally connected to the motor to control the reciprocal or rotational movement of the at least one pump member;
the controller being configured to vary the temporal distribution of motor force or torque actuating the reciprocal or rotational movement of the at least one pump member within a single pump cycle so as to control the flow delivery distribution of the flow delivered by the pump wherein the controller being operable to reduce the flow delivery fluctuations relative to a sinusoidal motor actuation. - View Dependent Claims (64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74)
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75. A method of designing a reactor for reacting at least two reactants diluted by a diluent to form a reaction product, the reactor comprising:
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a duct having an axial direction and a first and second transverse directions mutually distinct from the axial direction, the first and second transverse directions defining a plane through an axial location, with the area of the plane constrained within the inner surface of the duct defining a cross-sectional area of the duct at the axial location;
a first reactant distribution portion comprising at least one tubular portion having an outer surface and an inner surface, the inner surface defining a first flow path for the first fluid, and a plurality of first fluid distribution orifices extending from the inner surface to the outer surface, the plurality of first reactant distribution orifices having a spatial density distribution and a size distribution with respect to at least one of the transverse directions;
a diluent distribution portion comprising at least one diluent tubular portion having an outer surface and an inner surface, the inner surface defining a first diluent flow path for the diluent, and a plurality of diluent orifices extending from the inner surface to the outer surface of the diluent tubular portion, the plurality of diluent orifices having a spatial density distribution and size distribution with respect to at least one of the transverse directions;
the method comprising;
determining the desired delivery mass flow rates for a first reactant fluid comprising a first reactant, a second reactant fluid comprising a second reactant, and a diluent fluid, the fluid inlet parameters and the desired output pressure and temperature of the reaction product fluid exiting the reactor;
configuring the first reactant distribution portion;
configuring the duct which defines a second flow path for the second fluid;
determining a transverse distribution of axial velocity of the second fluid with respect to at least one of the transverse directions;
configuring the diluent distribution portion;
configuring the spatial density distribution and size distribution of the first reactant orifices with respect to at least one of the transverse directions; and
configuring the spatial density distribution and size distribution of the diluent orifices with respect to at least one of the transverse directions;
wherein achieving a desired transverse distribution, in at least one of the transverse directions, of at least one of the composition ratio of second reactant concentration to first reactant concentration, and the temperature of the product fluid, with respect to at least one of the transverse directions.
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76. A method of reacting a first reactant with a second reactant and mixing a diluent fluid with at least one of the first and second reactants and a reaction product to form a product fluid;
- the method comprising;
providing a reactor;
the reactor having an axial direction and a first and second transverse directions mutually distinct from the axial direction, the first and second transverse directions defining a plane through an axial location, with the area of the plane constrained within an inner surface of the reaction defining a cross-sectional area of the reactor at the axial location;
providing a first reactant delivery system to deliver a first reactant fluid comprising the first reactant to the reactor;
providing a second reactant delivery system to deliver a second reactant fluid comprising the second reactant to the reactor;
the second reactant delivery system comprising a diffuser that comprises a plurality of passages;
providing a diluent delivery system to deliver the diluent fluid to the reactor;
controlling the spatial delivery of the first reactant fluid into the reactor in at least one of the transverse directions;
controlling the spatial delivery of the diluent fluid into the reactor in at least one of the transverse directions; and
wherein controlling the at least one spatial distribution of the second reactant fluid and the diluent at least one of the transverse directions wherein controlling at least one of the composition, temperature, pressure and velocity of the reaction product, in at least one transverse direction near an exit of the reactor taken in a cross section of the reactor.
- the method comprising;
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77. A method of accurately controlling the composition of a reaction fluid formed by a reaction between two reactant fluids, the method comprising:
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delivering a first liquid reactant to a reactor through a reactant distributed contactor positioned within a duct in the reactor;
delivering a second fluid co-reactant through multiple fluid passages into the duct;
the duct having an axial direction and a first and second transverse directions mutually distinct from the axial direction, the first and second transverse directions defining a plane through an axial location, with the area of the plane constrained within an inner surface of the reaction defining a cross-sectional area of the reaction at the axial location;
configuring the reactant distributed contactor to control the spatial delivery of the first liquid reactant into the reactor in at least one of the transverse directions; and
measuring the residual component concentration of one of the reactant and the co-reactant;
wherein the measured residual component concentration is less than 15% of the concentration of the reactant or co-reactant within the reactor upstream of the reaction;
wherein the sensor measuring the residual component concentration is operable to measure the residual component concentration with an uncertainty of less than ±
0.5% of the total flow;
measuring the mass flow rate of first reactant with an uncertainty of less than ±
1% of the total flow;
sampling the reaction product at multiple locations across the reactor outlet sufficient to measure the residual component concentration wherein achieving an uncertainty of about ±
1% in the ratio of second reactant to first reactant.
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81. A method of controlling a pressurized reactor;
- the method comprising;
providing a reactor;
the reactor having an axial direction and a first and second transverse directions mutually distinct from the axial direction, the first and second transverse directions defining a plane through an axial location, with the area of the plane constrained within an inner surface of the reaction defining a cross-sectional area of the reaction at the axial location;
providing a first reactant delivery system to deliver a first reactant fluid comprising a first reactant to the reactor;
providing a second reactant delivery system to deliver a second reactant fluid comprising a second reactant to the reactor;
providing a diluent delivery system to deliver a diluent fluid comprising a vaporizable diluent to the reactor;
reacting a first reactant with a second reactant whereby forming a reaction product;
mixing a diluent fluid with at least one of the first and second reactants and a reaction product whereby forming a product fluid comprising a reaction product and diluent;
and controlling the delivery of diluent fluid and first reactant fluid to the reactor to control the pressure within the reactor to within specified compressor surge boundaries above which pressure causes surge in the second reactant delivery system. - View Dependent Claims (82, 83, 84)
- the method comprising;
Specification