Reactor system with unequal reactor assembly operating pressures

• US 11,090,624 B2
• Filed: 07/31/2018
• Issued: 08/17/2021
• Est. Priority Date: 07/31/2017
• Status: Active Grant

• Current Assignee: Ohio State Innovation Foundation (Ohio State University)
• Original Assignee: Ohio State Innovation Foundation (Ohio State University)
• Inventors: Fan, Liang-Shih, Wang, Dawei, Kathe, Mandar
• Primary Examiner(s): Hendrickson, Stuart L
• Application Number:
  US16/634,844
• Publication Number:
  US 20200156032A1
• Time in Patent Office: 1,113 Days
• CPC Class Codes: B01D 2253/102 Carbon
• CPC Class Codes: B01D 2253/104 Alumina
• CPC Class Codes: B01D 2253/108 Zeolites
• CPC Class Codes: B01D 2253/116 Molecular sieves other than zeolites
• CPC Class Codes: B01D 2256/10 Nitrogen
• CPC Class Codes: B01D 2256/16 Hydrogen
• CPC Class Codes: B01D 2257/104 Oxygen
• CPC Class Codes: B01D 2257/304 Hydrogen sulfide
• CPC Class Codes: B01D 2257/502 Carbon monoxide
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 53/047 Pressure swing adsorption
• CPC Class Codes: B01J 2208/00778 Kinetic energy reducing devices in the flow channel
• CPC Class Codes: B01J 8/003 in a downward flow
• CPC Class Codes: B01J 8/0035 Periodical feeding or evacuation
• CPC Class Codes: B01J 8/005 Separating solid material from the gas/liquid stream separation processes per se B01D
• CPC Class Codes: B01J 8/0492 Feeding reactive fluids for solid material, see B01J8/0015
• CPC Class Codes: B01J 8/085 Feeding reactive fluids for solid material, see B01J8/0015
• CPC Class Codes: B01J 8/1827 the fluidising gas being a reactant
• CPC Class Codes: B01J 8/1872 Details of the fluidised bed reactor B01J8/1836 takes precedence
• CPC Class Codes: B01J 8/26 with two or more fluidised beds, e.g. reactor and regeneration installations
• CPC Class Codes: C01B 2203/025 : containing a partial oxidation step
• CPC Class Codes: C01B 2203/0255 : containing a non-catalytic partial oxidation step
• CPC Class Codes: C01B 2203/0283 : containing a CO-shift step, i.e. a water gas shift step
• CPC Class Codes: C01B 2203/042 : Purification by adsorption on solids
• CPC Class Codes: C01B 2203/047 : the impurity being carbon monoxide
• CPC Class Codes: C01B 2203/0475 : the impurity being carbon dioxide
• CPC Class Codes: C01B 3/16 : using catalysts
• CPC Class Codes: C01B 3/344 : using non-catalytic solid particles
• CPC Class Codes: C01B 3/42 : using moving solid particles
• CPC Class Codes: C01B 3/48 : followed by reaction of water vapour with carbon monoxide
• CPC Class Codes: C01B 3/56 : by contacting with solids; Regeneration of used solids C01B3/508 takes precedence
• CPC Class Codes: Y02C 20/40 : of CO2
• CPC Class Codes: Y02P 20/151 : Reduction of greenhouse gas [GHG] emissions, e.g. CO2
• CPC Class Codes: Y02P 20/52 : using catalysts, e.g. selective catalysts

Abstract

A reactor system comprising a first reactor assembly, a first pressure transition assembly, a second reactor assembly and a second pressure transition assembly.

Claims

1. A reactor system, comprising:

a first reactor including a plurality of solid particles and configured to operate at a pressure P1, wherein the first reactor is configured to convert the solid particles at the pressure P1 to second solid particles at the pressure P1, and discharge the second solid particles at the pressure P1 through a first reactor solids outlet;

a first pressure transition assembly in fluid communication with the first reactor solids outlet and a second reactor, the first pressure transition assembly comprising;

a first nonmechanical valve, a first mechanical valve, a second nonmechanical valve and a second mechanical valve,

the first nonmechanical valve being positioned between and in fluid communication with the first reactor and the first mechanical valve, the second nonmechanical valve being positioned between and in fluid communication with the first mechanical valve and the second mechanical valve, and

the first nonmechanical valve including a plurality of inert gas inlets, each of the plurality of inert gas inlets being in fluid communication with an inert gas source; and

each of the plurality of inert gas inlets being configured to provide a flow gas to move particles through the first nonmechanical valve;

the second nonmechanical valve including a plurality of inert gas inlets, each of the plurality of inert gas inlets being in fluid communication with an inert gas source, each of the plurality of inert gas inlets being configured to provide a flow gas to move particles through the first nonmechanical valve;

the second nonmechanical valve further includes a second nonmechanical valve gas inlet in fluid communication with a pressurized inert gas source, and a second nonmechanical valve gas outlet for releasing pressurized gas;

wherein the first pressure transition assembly is configured to receive the second solid particles at the pressure P1, transition the pressure surrounding the second solid particles from the pressure P1 to a pressure P2 that is different from the pressure P1, and discharge the second solid particles at the pressure P2;

the second reactor configured to operate at the pressure P2, wherein the second reactor is configured to receive the second solid particles at the pressure P2 from the first pressure transition assembly, convert the second solid particles at the pressure P2 to third solid particles at the pressure P2, and discharge the third solid particles at the pressure P2 through a second reactor solids outlet; and

a second pressure transition assembly in fluid communication with the second reactor and the first reactor, the second pressure transition assembly configured to receive third solid particles at the pressure P2, transition the pressure surrounding the third solid particles from the pressure P2 to a pressure P3 that is different from the pressure P2, and discharge the third solid particles at the pressure P3 from the second pressure transition assembly.

2. The reactor system of claim 1, wherein the first reactor further comprises:

a first reactor inlet configured to receive a first reactor feedstock that chemically, physically, or chemically and physically reacts with solid particles within the first reactor to form the second solid particles at the pressure P1.

3. The reactor system of claim 2, wherein the first reactor feedstock chemically, physically, or chemically and physically reacts with solid particles within the first reactor to further form a first reactor product, and wherein the first reactor further comprises a first reactor product outlet configured to discharge the first reactor product at the pressure P1.

4. The reactor system of claim 1, wherein each of the first and second pressure transition assemblies comprise one or more flow gas inlets, each configured to provide a flow gas to move particles within the transition assemblies through various portions of the transition assemblies.

5. The reactor system of claim 1, wherein the second reactor further includes a second reactor inlet configured to receive a second reactor feedstock that chemically, physically, or chemically and physically reacts with solid particles within the second reactor to form the third solid particles at the pressure P2.

6. The reactor system of claim 1, wherein the second reactor further includes a second reactor outlet configured to discharge a second reactor product at the pressure P2.

7. The reactor system of claim 1, wherein the pressure P3 is the same as the pressure P1, such that the second pressure transition assembly is configured to transition the pressure surrounding the third solid particles from the pressure P2 to the pressure P1 and discharge the third solid particles at the pressure P1 from the second pressure transition assembly, and wherein the third solid particles at the pressure P1 are the first solid particles at the pressure P1 received by the first reactor.

8. The reactor of claim 1, wherein the first solid particles are metal oxide particles, the second solid particles are reduced metal oxide particles, and the third solid particles are oxidized metal oxide particles.

9. The reactor system according to claim 1, wherein P2 is less than P1.

10. The reactor system of claim 1, further comprising a gas-solids separation unit between and in fluid communication with the second reactor and the first reactor, the gas-solids separation unit including a separation unit solids inlet configured to receive the third solid particles at either the pressure P2 or the pressure P3, a separation unit gas outlet configured to discharge gas surrounding the third particles from the gas-solids separation unit, and a separation unit solids outlet configured to discharge the third particles at either the pressure P2 or the pressure P3, respectively, from the gas-solids separation unit.

11. The reactor system of claim 1, further comprising:

a third reactor configured to operate at the pressure P3, wherein the third reactor is configured to receive the third solid particles at the pressure P3, convert the third solid particles at the pressure P3 to the first solid particles at the pressure P3, and discharge the first solid particles at the pressure P3; and

a third pressure transition assembly in fluid communication with the third reactor and the first reactor, the third pressure transition assembly configured to receive the first solid particles at the pressure P3, transition the pressure surrounding the first solid particles from the pressure P3 to the pressure P1, and discharge the first solid particles at the pressure P1 from the third transition assembly.

12. The reactor system of claim 1, wherein the reactor system does not include a compressor unit to compress reactant gases entering the reactor system or product gases leaving the reactor system.

13. The reactor system of claim 1, wherein the first pressure transition assembly further comprises at least one additional nonmechanical valve in fluid communication with and positioned between:

the first reactor and the first nonmechanical valve;

the first nonmechanical valve and the first mechanical valve;

the first mechanical valve and the second nonmechanical valve;

the second nonmechanical valve and the second mechanical valve; and

the second mechanical valve and the second reactor.

14. The reactor system of claim 1, wherein the first pressure transition assembly operates in:

a first mode wherein the pressure within the first and second nonmechanical valves is P1, the first mechanical valve is in a closed position, and a first plurality of the second solid particles at the pressure P1 are received by the first nonmechanical valve in a manner that prevents the first plurality of the second solid particles at the pressure P1 from coming into direct contact with the first mechanical valve;

a second mode wherein the first mechanical valve is in an open position, the second mechanical valve is in a closed position, the second nonmechanical valve gas inlet is in a closed position, and the second nonmechanical valve gas outlet is in a closed position, wherein the first nonmechanical valve is configured to discharge the first plurality of the second solid particles at the pressure P1 through the first mechanical valve and into the second nonmechanical valve, wherein subsequently the second nonmechanical valve receives the first plurality of the second solid particles at the pressure P1 in a manner that prevents the first plurality of the second solid particles at the pressure P1 from directly contacting the first or second mechanical valves;

a third mode wherein the first and second mechanical valves are in the closed position, the second nonmechanical valve gas inlet is in the closed position, and the second nonmechanical valve gas outlet is in the open position, whereupon the pressure surrounding the first plurality of the second solid particles in the second nonmechanical valve is transitioned from the pressure P1 to the pressure P2;

a fourth mode, wherein the first mechanical valve is in the closed position, the second mechanical valve is in the open position, and the second nonmechanical valve gas inlet and second nonmechanical valve gas outlet are each in the closed position, whereupon the second nonmechanical valve is configured to discharge the first plurality of the second solid particles at the pressure P2 from the second nonmechanical valve and through the second mechanical valve; and

a fifth mode, wherein the first and second mechanical valves are each in the closed position, the second nonmechanical valve gas inlet is in the open position, and the second nonmechanical valve gas outlet is in the closed position, whereupon the pressure within the second nonmechanical valve transitions from the pressure P2 to the pressure P1.

15. The reactor system of claim 1, wherein the second pressure transition assembly includes:

a third nonmechanical valve, a third mechanical valve, a fourth nonmechanical valve and a fourth mechanical valve, wherein the third nonmechanical valve is positioned between and in fluid communication with the second reactor and the third mechanical valve, the third mechanical valve is operable in an open and a closed position, the fourth nonmechanical valve is positioned between and in fluid communication with the third mechanical valve and the fourth mechanical valve, and the fourth mechanical valve is operable in an open and closed position, and wherein the fourth nonmechanical valve further includes a fourth nonmechanical valve gas inlet for receiving pressurized inert gas that is operable in an open and closed position, and a fourth nonmechanical valve gas outlet for releasing pressurized gas that is operable in an open and closed position.

16. The reactor system of claim 15, wherein the second pressure transition assembly further comprises a fifth nonmechanical valve in fluid communication with and positioned between:

the second reactor and the third nonmechanical valve;

the third nonmechanical valve and the third mechanical valve;

the third mechanical valve and the fourth nonmechanical valve; and

the fourth nonmechanical valve and the fourth mechanical valve.

17. The reactor system of claim 16, wherein the second pressure transition assembly operates in:

a first mode wherein the pressure within the third and fourth nonmechanical valves is P2, the third mechanical valve is in a closed position, and a first plurality of the third solid particles at the pressure P2 are received by the third nonmechanical valve in a manner that prevents the first plurality of the third solid particles at the pressure P2 from coming into direct contact with the third mechanical valve;

a second mode wherein the third mechanical valve is in an open position, the fourth mechanical valve is in a closed position, the fourth nonmechanical valve gas inlet is in a closed position, and the fourth nonmechanical valve gas outlet is in a closed position, wherein the third nonmechanical valve is configured to discharge the first plurality of the third solid particles at the pressure P2 through the third mechanical valve and into the fourth nonmechanical valve, wherein subsequently the fourth nonmechanical valve receives the first plurality of the third solid particles at the pressure P2 in a manner that prevents the first plurality of the third solid particles at the pressure P2 from coming into direct contact with the third or fourth mechanical valves;

a third mode wherein the third and fourth mechanical valves are in the closed position, and either the fourth nonmechanical valve gas outlet or the fourth nonmechanical valve gas inlet is in the open position, whereupon the pressure surrounding the first plurality of third solid particles in the fourth nonmechanical valve is transitioned from the pressure P2 to the pressure P3;

a fourth mode, wherein the third mechanical valve is in the closed position, the fourth mechanical valve is in the open position, and the fourth nonmechanical valve gas inlet and fourth nonmechanical valve gas outlet are each in the closed position, whereupon the fourth nonmechanical valve is configured to discharge the first plurality of the third solid particles at the pressure P3 from the fourth nonmechanical valve and through the fourth mechanical valve; and

a fifth mode, wherein the third and fourth mechanical valves are each in the closed position, and either the fourth nonmechanical valve gas inlet or the fourth nonmechanical valve gas outlet is in the open position, whereupon the pressure within the second nonmechanical valve transitions from the pressure P3 to the pressure P2.