Reactor vessels with pressure and heat transfer features for producing hydrogen-based fuels and structural elements, and associated systems and methods

• US 8,926,908 B2
• Filed: 11/26/2012
• Issued: 01/06/2015
• Est. Priority Date: 02/13/2010
• Status: Expired due to Fees

• Current Assignee: Advanced Green Innovations, LLC
• Original Assignee: McAlister Technologies, LLC
• Inventors: McAlister, Roy Edward
• Primary Examiner(s): YOUNG, NATASHA E
• Application Number:
  US13/684,743
• Publication Number:
  US 20130309164A1
• Time in Patent Office: 771 Days
• Field of Search: 700/301, 422/105, 422/112, 422/113, 422/129, 422/187, 422/198, 422/110, 423/644, 423/648.1, 502702-704
• US Class Current: 422/110
• CPC Class Codes: B01J 19/0006 Controlling or regulating processes controlling or regulating in general G05
• CPC Class Codes: B01J 19/0013 Controlling the temperature of the process
• CPC Class Codes: B01J 19/127 Sunlight; Visible light
• CPC Class Codes: B01J 19/1812 Tubular reactors
• CPC Class Codes: B01J 19/20 in the form of helices, e.g. screw reactors
• CPC Class Codes: B01J 19/245 placed in series
• CPC Class Codes: B01J 2219/00074 by indirect heating or cooling employing heat exchange fluids
• CPC Class Codes: B01J 2219/00085 Plates; Jackets; Cylinders
• CPC Class Codes: B01J 2219/00144 Sunlight; Visible light
• CPC Class Codes: B01J 2219/00162 controlling the pressure
• CPC Class Codes: B01J 2219/00164 controlling the flow
• CPC Class Codes: B01J 2219/0801 Controlling the process
• CPC Class Codes: B01J 2219/0871 Heating or cooling of the reactor
• CPC Class Codes: B01J 2219/0875 Gas
• CPC Class Codes: B01J 2219/1203 Incoherent waves
• CPC Class Codes: B01J 2219/187 inclined at an angle to the horizontal or to the vertical plane
• CPC Class Codes: B01J 2219/24 Stationary reactors without moving elements inside
• CPC Class Codes: C01B 2203/0266 containing a decomposition step
• CPC Class Codes: C01B 2203/04 containing a purification step for the hydrogen or the synthesis gas
• CPC Class Codes: C01B 2203/0465 Composition of the impurity
• CPC Class Codes: C01B 2203/0485 : the impurity being a sulfur compound
• CPC Class Codes: C01B 2203/0811 : by combustion of fuel
• CPC Class Codes: C01B 2203/0822 : the fuel containing hydrogen
• CPC Class Codes: C01B 2203/0872 : Methods of cooling
• CPC Class Codes: C01B 2203/0883 : by indirect heat exchange
• CPC Class Codes: C01B 3/02 : Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
• CPC Class Codes: C01B 3/24 : of hydrocarbons
• CPC Class Codes: C01B 3/26 : using catalysts
• CPC Class Codes: C10B 23/00 : Other methods of heating coke ovens
• CPC Class Codes: C10B 53/02 : of cellulose-containing material production of pyroligneous acid C10C5/00
• CPC Class Codes: C10J 2300/1284 : by renewable energy, e.g. solar energy, photovoltaic cells, wind
• CPC Class Codes: C10J 2300/1665 : to alcohols, e.g. methanol or ethanol
• CPC Class Codes: C10J 2300/1884 : with one stream being synthesis gas
• CPC Class Codes: C10J 2300/1892 : with one stream being water/steam
• CPC Class Codes: C10J 3/20 : Apparatus; Plants
• CPC Class Codes: C10J 3/72 : Other features
• CPC Class Codes: C10J 3/723 : Controlling or regulating the gasification process
• CPC Class Codes: F23G 5/02 : with pretreatment
• CPC Class Codes: F23G 7/00 : Incinerators or other apparatus for consuming industrial waste, e.g. chemicals incinerator closets A47K11/02; oxidation of sludge C02F11/06; burners in general, burner details F23D; incinerating radioactive waste G21F9/00
• CPC Class Codes: F24S 20/20 : Solar heat collectors for receiving concentrated solar energy, e.g. receivers for solar power plants
• CPC Class Codes: F24S 20/40 : Solar heat collectors combined with other heat sources, e.g. using electrical heating or heat from ambient air
• CPC Class Codes: F24S 20/61 : Passive solar heat collectors, e.g. operated without external energy source
• CPC Class Codes: F24S 23/00 : Arrangements for concentrating solar-rays for solar heat collectors
• CPC Class Codes: G01M 3/223 : for pipe joints or seals
• CPC Class Codes: G01N 1/405 : by adsorption or absorption
• CPC Class Codes: G01N 2001/021 : Correlating sampling sites with geographical information, e.g. GPS
• CPC Class Codes: G01N 35/00613 : Quality control
• CPC Class Codes: G01N 35/00871 : Communications between instruments or with remote terminals
• CPC Class Codes: Y02B 10/20 : Solar thermal
• CPC Class Codes: Y02E 10/40 : Solar thermal energy, e.g. solar towers
• CPC Class Codes: Y02E 20/12 : Heat utilisation in combustion or incineration of waste
• CPC Class Codes: Y02E 50/10 : Biofuels, e.g. bio-diesel
• CPC Class Codes: Y02E 50/30 : Fuel from waste, e.g. synthetic alcohol or diesel
• CPC Class Codes: Y02E 60/32 : Hydrogen storage
• CPC Class Codes: Y02E 60/36 : Hydrogen production from non-carbon containing sources, e.g. by water electrolysis
• CPC Class Codes: Y02P 20/10 : Process efficiency
• CPC Class Codes: Y02P 20/129 : Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines
• CPC Class Codes: Y02P 20/133 : Renewable energy sources, e.g. sunlight
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Reactor vessels with pressure and heat transfer features for producing hydrogen-based fuels and structural elements, and associated systems and methods. A representative reactor system includes a first reaction zone and a heat path, a reactant source coupled to the first reaction zone, and a first actuator coupled to cyclically pressurize the first reaction zone. A second reaction zone is in fluid communication with the first, a valve is coupled between the first and second reaction zones to control a flow rate therebetween, and a second actuator is coupled in fluid communication with the second reaction zone to cyclically pressurize the second reaction zone. First and second heat exchangers direct heat from products to reactants in the reaction zones. A controller controls the first and second actuators in a coordinated manner based at least in part on a flow rate of the second product from the second reaction zone.

Claims

1. A chemical reactor system, comprising:

a first reaction zone and a heat path positioned to direct primary heat into the first reaction zone;

a reactant source coupled to the first reaction zone;

a second reaction zone in fluid communication with the first reaction zone;

a secondary heat source coupled to the first reaction zone;

a solar input sensor;

a flow rate control mechanism coupled between the first and second reaction zones for controlling a flow rate between the first and second reaction zones; and

a controller programmed with cyclical pressurization instructions that, when executed;

cyclically pressurize the first reaction zone;

cyclically pressurize the second reaction zone in a manner that depends at least in part on a flow of a product from the first reaction zone to the second reaction zone; and

actuate the secondary heat source in response to an input from the solar input sensor corresponding to low solar input to the first reaction zone.

2. The system of claim 1, further comprising:

a first heat exchanger positioned to direct heat from a first product leaving the first reaction zone to a reactant entering the first reaction zone;

a second heat exchanger positioned to direct heat from a second product leaving the second reaction zone to the reactant entering the first reaction zone.

3. The system of claim 2 wherein:

the first heat exchanger is positioned in fluid communication with the first and second reaction zones and has;

a first flow path positioned to direct products from the first reaction zone into the second reaction zone; and

a second flow path in thermal communication with the first flow path and coupled between the reactant source and the first reaction zone; and

wherein

the second heat exchanger is positioned in fluid communication with the second reaction zone and has;

a third flow path positioned to direct products from the second reactor; and

a fourth flow path in thermal communication with the second flow path and coupled between the reactant source and the first reaction zone.

4. The system of claim 1 wherein the controller is programmed with cyclical pressurization instructions that, when executed:

direct a first actuator to cyclically pressurize the first reaction zone; and

direct a second actuator to cyclically pressurize the first second reaction zone in a manner that is correlated with pressurization of the first reaction zone.

5. The system of claim 1 wherein the heat path includes a reactor surface transmissive to solar energy, and wherein the system further comprises a solar collector positioned to direct solar radiation through the reactor surface.

6. The system of claim 1 wherein the mechanism includes a check valve positioned to admit the first product into the second reaction zone when the pressure in the first reaction zone is greater than the pressure in the second reaction zone, and prevent fluid communication between the first and second reaction zones when the pressure in the second reaction zone is greater than the pressure in the first reaction zone.

7. The system of claim 1 wherein the controller is programmed with cyclical pressurization instructions that cyclically pressurize the first reaction zone by directing pressurized reactant into the first reaction zone.

8. A chemical reactor system, comprising:

a cylindrical housing having a longitudinal axis;

a first reaction zone and a heat path positioned to direct primary heat into the first reaction zone, the first reaction zone being housed within the cylindrical housing;

a reactant source coupled to the first reaction zone;

a second reaction zone in fluid communication with the first reaction zone and housed within the cylindrical housing;

a concave solar collector actuatable to direct solar energy to the first reaction zone or the second reaction zone;

a flow rate control mechanism coupled between the first and second reaction zones to control a flow rate between the first and second reaction zones; and

a controller operatively coupled to the flow rate control mechanism, the controller being programmed with cyclical pressurization instructions that, when executed;

cyclically pressurize the first reaction zone;

cyclically pressurize the second reaction zone in a manner that depends at least in part on a flow of a product from the first reaction zone to the second reaction zone.

9. The chemical reactor system of claim 8, wherein the first reaction zone and the second reaction zone are aligned along the longitudinal axis of the cylindrical housing.

10. The chemical reactor system of claim 8, wherein the concave solar collector is positionable along the longitudinal axis of the cylindrical housing.