Reactor Systems for Gas Synthesis

A method for producing ammonia from synthesis gas containing hydrogen and nitrogen combined with any recycle streams, the process comprising the steps of:

• (a) supplying synthesis feed gas to a system comprising one or more catalyst filled pressure vessel reactors, each catalyst filled pressure vessel reactor being connected to one or more manifolds at the inlet and one or more manifolds at the outlet of the system, each catalyst filled pressure vessel reactor being equipped with an independently operated mechanism to control, direct and stop the flow of fluids to or from the individual vessel and catalyst bed via said inlet and outlet manifolds;
• (b) opening the control mechanism of a selected catalyst filled pressure vessel reactor or group of catalyst filled pressure vessel reactors to enable sufficient synthesis feed gas to pass into each catalyst filled pressure vessel reactor from its inlet manifold such that it is filled with the feed gas and pressurized to a selected operating pressure;
• (c) closing the control mechanisms at each end of the selected catalyst filled pressure vessel reactor or group of reactors once filled with feed gas to stop or sufficiently slow the flow of gas in contact with the catalyst to allow the reaction to take place;
• (d) timing, predicting or monitoring temperature, pressure or other measurable states within each closed or partially closed catalyst filled pressure vessel reactor to determine the reaction progression;
• (e) allowing the catalyst filled pressure vessel reactor or reactors to cool below the ammonia product critical point or dew point temperature once the reaction has reached a desired state, conversion or equilibrium conversion;
• (f) expelling liquid ammonia product that collects at the lower portion of the catalyst filled pressure vessel reactor or reactors once sufficiently cooled, without allowing the majority of unreacted gasses to escape the catalyst filled pressure vessel reactor or reactors;
• and
• (g) repeating the filling process by adding new synthesis feed gas to any unreacted gasses remaining in the catalyst filled pressure vessel reactor or reactors.