Device and method for catalytic gas phase reaction and the use thereof

An improved reactor for catalytic, exothermic gas-phase reactions by reaction of a feed gas to form a product gas, which comprises:

• viewed in the flow direction of the feed gas, an inlet zone (1), a reaction zone (2) containing at least one catalyst (4) and an outlet zone (3) for the product gas, a feed gas mixture being introduced into the inlet zone (1),
• wherein the improvement comprises:
• means chosen from the group consisting of first means for reducing heat transport from the reaction zone (2) to the inlet zone (1) comprising at least one insulating liner (6) which insulates the interior space of the reactor from the reactor wall (5) over a region extending at least the height of the inlet zone (1) and optionally through a region extending the combined height of the inlet zone (1) and the reaction zone (2);
• second means for reducing heat transport from the reaction zone (2) to the inlet zone (1) comprising at least one apparatus for conveying a cooling medium, said apparatus being located at a position in the region of the inlet zone (1) and optionally extending through the reaction zone (2),
• means for preventing undesired reactions at the reactor wall, comprising at least the inner surfaces of interior walls of the reactor comprising inert material at least in the region of the inlet zone (1) and optionally through both the region of the inlet zone (1) and the reaction zone (2);
• and
• combinations of any of the preceding.

An improved process for carrying out catalytic, exothermic gas-phase reactions using a reactor which comprises:

• viewed in the flow direction of the feed gas, an inlet zone (1), a reaction zone (2) containing at least one catalyst (4) and an outlet zone (3) for the product gas, a feed gas mixture being introduced into the inlet zone (1), said process comprising:
• i) introducing a feed gas mixture into the inlet zone (1) of a reactor,
• ii) passing the feed gas mixture into a reaction zone (2) containing a catalyst (4) while maintaining conditions in the reaction zone (2) under which the feed gas mixture is at least partially converted into products in an exothermic reaction occurring in the reaction zone (4),
• iii) discharging the product gas mixture from the reactor via an outlet zone (3) wherein the improvement is chosen from the group consisting of:
• a. reducing heat transport from the reaction zone (2) to the inlet zone (1) by providing at least one insulating liner (6) which insulates the interior space of the reactor from the reactor wall (5) over a region extending at least the height of the inlet zone (1) and optionally through a region extending the combined height of the inlet zone (1) and the reaction zone (2);
• b. reducing heat transport from the reaction zone (2) to the inlet zone (1) by conveying a cooling medium, said apparatus to a position in the region of the inlet zone (1) and optionally extending through the reaction zone (2),
• c. preventing undesired reactions at the reactor wall, by providing inert material over at least the inner surfaces of interior walls of the reactor at least in the region of the inlet zone (1) and optionally through both the region of the inlet zone (1) and the reaction zone (2);
• and
• d. combinations of any of the preceding.

A reactor for catalytic, exothermic gas-phase reactions by reaction of a feed gas to form a product gas, which comprises, viewed in the flow direction of the feed gas, an inlet zone, a reaction zone containing at least one catalyst and an outlet zone for the product gas, wherein a feed gas mixture is introduced into the inlet zone,

• a. at least one insulating liner insulating at least a portion of the reactor wall from the interior space of the reactor, said insulating liner extending through a region including at least the height of the inlet zone up to and including extending through the region including the combined height of both the inlet zone and the reaction zone;
• and
• b. at least one means for reducing heat transport from the reaction zone into the inlet zone by conveying a cooling medium is provided at a location which is located in the region including at least the inlet zone and extending through the reaction zone;
• wherein the interior walls of the reactor consist of inert material in a region of the reactor which extends at least through the inlet zone of the reactor up to extending through the inlet zone and the reaction zone.