Chemical reaction process utilizing fluid-wall reactors

A high temperature fuel conversion process for converting a carbonaceous feedstock, water, and molecular oxygen into a synthesis gas mixture containing carbon monoxide and hydrogen which comprises:

• a. generating an annular envelope of an inert fluid which is substantially transparent to radiation within a shell of a refractory material which reflects radiation;
• the volume enclosed by the shell constituting a black body cavity, the envelope having substantial axial length and the interior of the envelope defining a reaction chamber;
• b. passing the carbonaceous feedstock into the black body cavity and into the reaction chamber along a predetermined path substantially coincident with the longitudinal axis of the envelope;
• c. introducing water into the reaction chamber along at least a portion of the predetermined path of the carbonaceous feedstock;
• d. introducing molecular oxygen into the reaction chamber along at least a portion of the predetermined path of the carbonaceous feedstock;
• and
• e. directing high intensity radiant energy into the reaction chamber to coincide with at least a portion of the predetermined path of the feedstock, sufficient radiant energy being absorbed within the reaction chamber to raise the temperature of reactants in the chamber to a level to a level required to initiate and sustain the conversion of the reactants into the synthesis gas mixture.

A high temperature fuel conversion process utilizing a high temperature fluid-wall reactor for converting a carbonaceous feedstock, steam, and molecular oxygen into a synthesis gas mixture containing carbon monoxide and hydrogen, which reactor comprises:

• A. a reactor tube having an inlet end and an outlet end, the interior of the tube defining a reactor chamber, the reactor tube being made of a porous refractory material capable of emitting sufficient radiant energy to raise the temperature of reactants within the reactor tube to a level required to initiate and sustain the desired fuel conversion reaction;
• the pores of the refractory material being of such diameter as to permit a uniform flow of sufficient inert fluid which is substantially transparent to radiant energy through the tube wall to constitute a protective blanket for the radially inward surface of the reactor tube;
• B. a fluid-tight, tubular pressure vessel enclosing the reactor tube to define an inert fluid plenum between the reactor tube and the pressure vessel, the inlet and outlet ends of the reactor tube being sealed from the plenum;
• the pressure vessel having an inlet for admitting the inert fluid which is directed under pressure into the plenum and through the porous tube wall into the reactor chamber;
• C. means for introducing the carbonaceous feedstock into the reactor chamber through the inlet end of the reactor tube, the carbonaceous feedstock being directed in a predetermined path axially of the reactor tube and being confined by the protective blanket substantially centrally within the reactor chamber and out of contact with the inner wall of the reactor tube;
• D. means for introducing steam and molecular oxygen into the reactor chamber along at least a portion of the predetermined path of the carbonaceous feedstock;
• E. electrical means disposed within the plenum and spaced radially outwardly of the reactor tube for heating the reactor tube to the temperature level at which it emits sufficient radiant energy to initiate and sustain the desired fuel conversion reaction, the radiant energy being directed centrally therewithin substantially coincident with at least a portion of the path of the carbonaceous feedstock;
• and
• F. a circumferential heat shield disposed within the pressure vessel and radially outwardly of the heating means, the heat shield reflecting radiant energy toward the reactor tube;
• the high temperature fuel conversion process which comprises:
• 1. generating within the interior of the porous reactor tube an annular envelope constituting an inert fluid which is substantially transparent to radiant energy to form a protective blanket for the radially inward surface of the reactor tube, the annular envelope having substantial axial length;
• 2. passing the carbonaceous feedstock into the reaction chamber along a predetermined path substantially coincident with the longitudinal axis of the envelope and out of contact with the inner wall of the reactor tube;
• 3. introducing steam into the reaction chamber along at least a portion of the predetermined path of the carbonaceous feedstock;
• 4. introducing molecular oxygen into the reaction chamber along at least a portion of the predetermined path of the carbonaceous feedstock;
• and
• 5. directing high intensity radiant energy into the reaction chamber to coincide with at least a portion of the predetermined path of the carbonaceous feedstock, sufficient radiant energy being absorbed within the reaction chamber to raise the temperature of the reactants to a level required to initiate and sustain the conversion of the reactants into the synthesis gas mixture.