US 6,015,540 A · Method and apparatus for thermally reacting chemicals in a matrix bed

Abstract

An improved method and apparatus is provided for thermally reacting chemicals in a matrix bed of porous inert media. The reaction is conducted in an apparatus that is capable of establishing and maintaining a non-planar reaction wave within the matrix bed. The positioning of the non-planar reaction wave permits the interior surfaces of the vessel to be maintained at a temperature at least above 175.degree. F. The apparatus includes a vessel that contains the matrix bed; one or more feed tubes that extend into the matrix bed, where preferably an exterior portion of each of the feed tubes that passes through the vessel is insulated; an exhaust outlet; and a means for heating the matrix bed. The non-planar reaction wave is established by heating at least a portion of the matrix bed to at least the reaction temperature of the chemicals and feeding a process stream containing the chemicals to be reacted into the feed tubes. Upon exiting the feed tubes, the process stream is reacted in a non-planar reaction wave to produce heat and the reacted process stream. The heat from the non-planar reaction wave maintains the interior surfaces of the vessel at a temperature of at least 175.degree. F. during operation of the vessel. The reacted process stream is then directed to the exhaust outlet of the vessel.

Claims42

Dependent claims

A method of reacting one or more chemicals in a vessel having a matrix bed of porous inert media comprising the steps of:

a) forming a process stream comprising the chemicals;
b) heating at least a portion of the matrix bed to at least the reaction temperature of the one or more chemicals;
c) feeding the process stream into the vessel through one or more feed tubes extending into the matrix bed, wherein each of the feed tubes has an entrance end, an exit end, an interior surface, and an exterior surface, and wherein the vessel has interior surfaces, an entrance side for receiving the feed tubes, an end side opposite to the entrance side, and an exhaust outlet;
d) directing the process stream through the feed tubes and into the matrix bed, wherein the process stream exiting the feed tubes is homogeneous and at a temperature below the reaction temperature of the one or more chemicals;
e) establishing and maintaining at least one non-planar reaction wave in the matrix bed, wherein at least a portion of the chemicals are reacted in the non-planar reaction wave to form a reacted process stream and heat and the heat from the non-planar reaction wave maintains the interior surfaces of the vessel at a temperature of at least about 175.degree. F. during operation of the vessel;
and
f) directing the reacted process stream, countercurrent to the flow of the process stream in the feed tubes, through the matrix bed and into the exhaust outlet of the vessel.

4 more elements

An apparatus for reacting chemicals in a matrix bed comprising:

a) a vessel having interior surfaces, an entrance side, an end side opposite to the entrance side, and at least one exhaust outlet;
b) a matrix bed comprising porous inert media, wherein the matrix bed is contained within the vessel;
c) a void space located between the matrix bed and entrance side of the vessel, wherein the exhaust outlet is connected to the matrix bed or void space;
d) one or more feed tubes, wherein the feed tubes enter the vessel through the entrance side of the vessel and extend into the matrix bed and have an inlet end, an exit end, an interior surface, and an exterior surface, wherein at least a portion of the exterior of each of the feed tubes that passes through the entrance side of the vessel is insulated, and wherein the ratio of the length of the feed tube contained within the vessel to the vessel length measured from the vessel end to the vessel exhaust outlet is from about 0.1 to about 0.9 and the total cross sectional area of the feed tubes to the vessel cross-sectional area is from about 0.005 to about 0.5;
e) means for heating at least a portion of the matrix bed to the reaction temperature of the one or more chemicals;
f) a mixing device capable of providing a process stream through the feed tubes to the matrix bed in a homogeneous form;
and
g) means for maintaining at least one non-planar reaction wave in the matrix bed in a manner such that the non-planar reaction wave provides heat for maintaining the interior surfaces of the vessel at a temperature of at least about 175.degree. F.

5 more elements

Dependencies are inferred from the claim text.

Method and apparatus for thermally reacting chemicals in a matrix bed

Life of this patent

Method and apparatus for thermally reacting chemicals in a matrix bed

Life of this patent

Abstract

Claims42