Catalytic reactor having radial leaves

• US 20060263278A1
• Filed: 05/19/2005
• Published: 11/23/2006
• Est. Priority Date: 05/19/2005
• Status: Active Grant

• Current Assignee: Johnson Matthey PLC
• Original Assignee: Catacel Corporation (Johnson Matthey PLC)
• Inventors: Becker, David A., Whittenberger, William A.
• Granted Patent: US 7,682,580 B2
• Time in Patent Office: Days
• US Class Current: 422/211
• CPC Class Codes: B01J 19/249 Plate-type reactors
• CPC Class Codes: B01J 2219/2455 Plates arranged radially
• 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 2219/2459 Corrugated plates
• 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 2219/2493 Means for assembling plates together, e.g. sealing means, screws, bolts
• CPC Class Codes: B01J 2219/2495 the plates being assembled interchangeably or in a disposable way
• CPC Class Codes: B01J 2219/2498 Additional structures inserted in the channels, e.g. plates, catalyst holding meshes
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: C01B 2203/02 Processes for making hydrogen or synthesis gas
• CPC Class Codes: C01B 2203/066 with fuel cells
• CPC Class Codes: C01B 2203/1035 Catalyst coated on equipment surfaces, e.g. reactor walls
• CPC Class Codes: C01B 3/38 using catalysts
• CPC Class Codes: C01B 3/384 the catalyst being continuously externally heated
• CPC Class Codes: Y02P 20/52 using catalysts, e.g. selective catalysts

Abstract

A reactor includes a plurality of metal leaves which extend from an interior of the reactor to its exterior. The leaves occupy a space between an internal mandrel and an external tube. In one embodiment, the leaves are generally flat pieces of foil, stacked together so that they do not touch except at spacers formed in the pieces. In another embodiment, the leaves are formed of a pleated and crimped foil, each leaf being defined by a piece of foil that has been folded over upon itself. In both embodiments, the leaves extend from the internal mandrel, radially outward to an inner surface of the tube. The reactor facilitates the transfer of heat between the outside of the reactor and its inside region.

Claims

1. A reactor comprising a plurality of metal leaves, each leaf extending from an interior region to an exterior of the reactor, at least a portion of each leaf being spaced apart from an adjacent leaf.

2. The reactor of claim 1, wherein at least some of the leaves are coated with a catalyst.

3. The reactor of claim 1, wherein the interior region is bounded by a generally cylindrical pipe, and wherein the exterior of the reactor is bounded by a generally cylindrical tube, and wherein the leaves occupy a region exterior to said pipe and interior to said tube.

4. The reactor of claim 3, wherein each leaf comprises a piece of metal foil having a flat central region and at least one flat edge portion angled relative to the central region.

5. The reactor of claim 4, wherein the edge portion makes an angle of less than about five degrees relative to the central region.

6. The reactor of claim 4, further comprising means for preventing the leaves from moving axially.

7. The reactor of claim 3, wherein each leaf includes spacers for maintaining a separation between the leaf and its adjacent leaves.

8. The reactor of claim 7, wherein the spacers comprise bumps formed in the leaves, the bumps of a given leaf being offset relative to the bumps of adjacent leaves.

9. The reactor of claim 3, wherein each leaf comprises a piece of metal foil which is folded over upon itself.

10. The reactor of claim 3, wherein the leaves are formed of a pleated metal foil, and wherein pairs of pleats of the foil are compressed together to define the leaves.

11. The reactor of claim 10, wherein the foil forming the leaves is coated with catalyst only on one side, wherein the leaves are coated only on a side which is in contact with the exterior of the reactor.

12. The reactor of claim 10, wherein the leaves are spaced apart from each other near the exterior region of the reactor, and wherein the leaves are compressed together near the interior region of the reactor.

13. A method of making a reactor, comprising:

a) arranging a plurality of metal leaves around a mandrel, wherein each leaf has an edge which is positioned to contact the mandrel, and

b) inserting the leaves and mandrel within a tube, wherein the leaves occupy a space between the mandrel and the tube, and wherein each leaf extends from the mandrel to an inner surface of the tube.

14. The method of claim 13, wherein step (a) is preceded by the step of forming spacers in the leaves, the spacers of a given leaf being offset relative to the spacers of an adjacent leaf, wherein the leaves, when inserted within the space between the mandrel and the tube, do not contact each other except through the spacers.

15. The method of claim 13, wherein step (a) is preceded by the step of coating the leaves with a catalyst.

16. The method of claim 13, further comprising enclosing the leaves within at least one band.

17. The method of claim 13, further comprising affixing at least one washer to the mandrel so as to prevent the leaves from moving axially.

18. A method of making a reactor, comprising:

a) corrugating a piece of metal so as to form a plurality of pleats in the metal,

b) crimping ends of at least some of said pleats,

c) arranging the crimped, pleated metal around a mandrel, and

d) inserting the structure formed in step (c) within a tube,

wherein the crimped, pleated metal defines a plurality of leaves which occupy a space between the mandrel and the tube.

19. The method of claim 18, wherein step (b) is followed by welding at least some of the crimped pleats together.

20. The method of claim 18, further comprising forming spacers in at least a portion of at least some of the pleats, so as to hold the pleats apart in locations near an exterior region of the reactor.

21. The method of claim 18, further comprising the step of coating said piece of metal with catalyst on only one side.