# US 2019/0375634 A1 · Multi-tubular chemical reactor with igniter for initiation of gas phase exothermic reactions

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- Number: US 2019/0375634 A1
- Document ID: US20190375634A1
- Status: Published application
- Kind: A1
- Application number: 16/515,608
- Filed: 2019-07-18
- Published: 2019-12-12
- Earliest claimed: 2013-11-06
- Assignees: WATT Fuel Cell Corp.
- Applicants: Watt Fuel Cell Corp.
- Inventors: CAINE M. FINNERTY; Paul DeWald
- Web page: https://patentgrep.com/patent/US20190375634A1

## CPC

- C01B 3/386: Catalytic partial combustion
- B01J 4/001: {Feed or outlet devices as such, e.g. feeding tubes}
- B01J 4/002: {Nozzle-type elements (nozzle-type reactors B01J19/26)}
- B01J 4/005: {provided with baffles}
- B01J 7/00: Apparatus for generating gases (production of inert gas mixtures B01J19/14; for generating specific gases, see the relevant subclasses, e.g. C01B, C10J {; in "air bags" on vehicles B60R21/26; for starter gas F02C7/26; blasting cartridges for producing gas under pressure F42B3/04})
- B01J 8/0285: {Heating or cooling the reactor (for tubular reactors in furnaces B01J8/062)}
- B01J 8/065: {Feeding reactive fluids}
- B01J 8/067: {Heating or cooling the reactor (B01J8/062 takes precedence)}
- B01J 8/1836: {Heating and cooling the reactor (B01J8/42 takes precedence)}
- B01J 8/24: according to "fluidised-bed" technique (B01J8/20 takes precedence)
- B01J 12/005: {carried out at high temperatures, e.g. by pyrolysis}
- B01J 12/007: {in the presence of catalytically active bodies, e.g. porous plates}
- B01J 19/0013: {Controlling the temperature of the process}
- B01J 19/0093: {Microreactors, e.g. miniaturised or microfabricated reactors (laboratory containers with capillary fluid transport in microfabricated channels or chambers B01L3/5027)}
- B01J 19/2415: {Tubular reactors}
- B01J 19/2445: {placed in parallel}
- B01J 2208/00389: using electric heating or cooling elements
- B01J 2208/00902: Nozzle-type feeding elements
- B01J 2208/00911: Sparger-type feeding elements
- B01J 2219/00006: Large-scale industrial plants
- B01J 2219/00058: Temperature measurement
- B01J 2219/00063: of the reactants
- B01J 2219/00069: Flow rate measurement
- B01J 2219/00117: with two or more reactions in heat exchange with each other, such as an endothermic reaction in heat exchange with an exothermic reaction
- B01J 2219/00132: using electric heating or cooling elements
- B01J 2219/00135: Electric resistance heaters
- B01J 2219/00155: using insulating materials or refractories
- B01J 2219/00157: by means of a burner
- B01J 2219/00159: controlling multiple zones along the direction of flow, e.g. pre-heating and after-cooling
- B01J 2219/002: inside the reactor
- B01J 2219/00213: Fixed parameter value
- B01J 2219/00234: inside the reactor
- B01J 2219/00585: Parallel processes
- C01B 2203/0233: the reforming step being a steam reforming step
- C01B 2203/0244: the reforming step being an autothermal reforming step, e.g. secondary reforming processes
- C01B 2203/0261: containing a catalytic partial oxidation step [CPO]
- C01B 2203/0844: the non-combustive exothermic reaction being another reforming reaction as defined in groups C01B2203/02 - C01B2203/0294
- C01B 2203/085: by electric heating
- C01B 2203/1223: Methanol
- C01B 2203/1229: Ethanol
- C01B 2203/1235: Hydrocarbons
- C01B 2203/1241: Natural gas or methane
- C01B 2203/1247: Higher hydrocarbons
- C01B 2203/141: At least two reforming, decomposition or partial oxidation steps in parallel
- Y02E 60/50: Fuel cells
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A multi-tubular chemical reactor includes an igniter for the initiation of gas phase exothermic reaction within the gas phase reaction zones of the tubular reactor units.

## Claims

### Claim at position 1

1-9. (canceled)

### Claim 10

A method of carrying out a gas phase exothermic reaction within a multi-tubular chemical reactor to produce desired product(s), the method comprising:
introducing gaseous reactants into an inlet of a gaseous flow passageway of a plurality of reactor units, each reactor unit of the plurality comprising an elongate tube having a wall with an internal surface, an external surface, and a wall interior between the internal and external surfaces, at least a portion of the wall interior adapted to function as a gas phase reaction zone, the interior surface of the wall enclosing the gaseous flow passageway having the inlet at one end and an outlet at the opposing end, the interior surface of the wall adapted to permit gas flowing through the passageway to enter the wall interior at the gas phase reaction zone;
flowing at least a portion of the gaseous reactants into the as phase reaction zones of the plurality of reactor units;
initiating with radiant heat an exothermic reaction of the gaseous reactants within the gas phase reaction zone of at least one of the reactor units, thereby commencing the production of desired product(s) and exothermic heat; and
transferring heat produced by the exothermic reaction occurring within the gas phase reaction zone of the at least one reactor unit to the gas phase reaction zone of one or more adjacent reactor units, thereby initiating an exothermic reaction within the at least one adjacent reactor unit until in such manner an exothermic reaction has been initiated in each of the plurality of spaced-apart reactor units.

### Claim 11 (depends on 10)

The method of claim 10 wherein the initiating of the exothermic reaction in the at least one reactor unit comprises heating the at least one reactor unit with at least one igniter, the igniter comprising a radiant heat-producing element, wherein the radiant heat-producing element is positioned in thermal communication with and proximity to, but in physical isolation from, the gas phase reaction zone.

### Claim 12 (depends on 10)

The method of claim 10 comprising maintaining the exothermic reactions in the plurality of spaced-apart reactor units with the exothermic heat of the reactions in the plurality of reactor units.

### Claim 13

(canceled)

### Claim 14 (depends on 10)

The method of claim 10 wherein the exothermic reaction is catalytic partial oxidation.

### Claim 15 (depends on 10)

The method of claim 10, wherein the distance between adjacent reactor units is no more than the distance beyond which the exothermic reaction fails to be initiated in the adjacent reactor unit by the exothermic heat from the at least one adjacent reactor unit in which the exothermic reaction is occurring.

### Claim 16 (depends on 10)

The method of claim 10, comprising establishing a predetermined minimum array temperature value, and setting the maximum distance between adjacent reactor units as the distance at which the temperature of the plurality of spaced-apart reactor units falls below the predetermined minimum array temperature value.)

### Claim 17 (depends on 10)

The method of claim 10, comprising establishing a predetermined maximum temperature value, and setting the minimum distance between adjacent reactor units as the distance below which the temperature at an outlet of the gaseous flow passageway is greater than the predetermined maximum temperature value.

### Claim 18 (depends on 10)

The method of claim 10, wherein the exothermic reaction is autothermal reforming.

### Claim 19 (depends on 10)

The method of claim 10, wherein the reactor units are within a chamber, and measuring the temperature within the chamber with a thermocouple.

### Claim 20 (depends on 10)

The method of claim 10, wherein the exothermic reaction is initiated in multiple reactor units with multiple radiant heat electric igniters.

### Claim 21 (depends on 10)

The method of claim 10, wherein a plurality of electric radiant heat igniters, the plurality or reactor units and a plurality of thermocouples are all disposed within an insulated chamber, with one igniter at one end of the chamber opposite a thermocouple at the opposite end of the chamber.

### Claim 22 (depends on 10)

The method of claim 10, wherein the reactants of the exothermic reaction are fed into a conduit and mixed together and the mixed reactants are fed from the conduit into the inlet.

### Claim 23 (depends on 22)

The method of claim 22, wherein the reactants are gaseous fuel and air and mixing is performed with a static mixer within the conduit.

### Claim 24 (depends on 10)

The method of claim 10, comprising using a controller to control the operation of the multi-tubular chemical reactor, the controller in operative communication with at least one electric radiant heat igniter, at least one one thermocouple and a source of the gaseous reactants.

### Claim 25 (depends on 10)

The method of claim 10, wherein the gaseous reactants comprise methane, butane, or propane.

### Claim 26 (depends on 10)

The method of claim 10, wherein the gaseous reactants comprise vaporized diesel fuel, gasoline or kerosene.