Process and apparatus using plate arrangement for combustive reactant heating

A process for contacting reactants with a catalyst in a reaction zone while indirectly heating the reactants by contact with combustion gases formed in a heat producing zone, said process comprising:

• a) contacting a primary reactant stream comprising a methane containing stream and a steam containing stream with steam reforming catalyst in a plurality of narrow reaction channels defined by principal spaced apart plates to conduct a primary reforming reaction;
• b) indirectly heating the primary reactant stream in the reaction channels by heat exchange with a hot gas stream across the principal plates that define the reaction channels and that further define one or more heat exchange channels on a side opposite one or more reaction channels, wherein the heat exchange channels are divided by a plurality of secondary plates into oxidation channels and preheat channels,
• c) collecting a primary effluent stream from the reaction channels;
• d) passing an oxygen containing stream and at least a portion of the primary effluent stream or a portion of the methane containing stream to an oxidation zone contained within the oxidation channels to produce a secondary effluent stream;
• e) passing at least a portion of the secondary effluent stream through the preheat channels into contact with the principal plates to supply the hot gas stream for indirect heat exchange with the reaction channels as described in step (b);
• and,
• f) recovering a synthesis gas comprising at least a portion of the primary effluent stream or the secondary effluent steam.

A process for contacting reactants with a catalyst in a reaction zone while indirectly heating the reactants by contact with combustion gases formed in a heat producing zone, said process comprising:

• a) contacting a feedstock comprising methane and steam with a steam reforming catalyst in a plurality of narrow reaction channels defined by a plurality of principal spaced apart plates;
• b) indirectly heating the feedstock in the reaction channels by heat exchange with a hot gas stream that passes through heat exchange channels defined by the principal plates and interleaved with the reaction channels, the heat exchange channels divided by a plurality of secondary plates into oxidation channels and preheat channels;,
• c) collecting a primary effluent stream from the reaction channels;
• d) passing an oxygen containing stream and at least a portion of the primary effluent stream to an oxidation zone contained within the oxidation channels to produce a secondary effluent stream;
• e) passing at least a portion of the secondary effluent stream through the preheat channels into contact with the plates in the heat exchange channels to indirectly heat the reaction channels as described in step (b);
• and,
• f) recovering a synthesis gas comprising at least a portion of the secondary effluent stream.

An apparatus for contacting reactants with a catalyst in a reaction zone while indirectly heating the reactants by contact with combustion gases formed in a heat producing zone, the apparatus comprising:

• a plurality of alternate reaction channels and heat exchange channels defined by a plurality of primary plates to have a reactant inlet at one end of the reaction channels, a reactant outlet at an opposite end of the reaction channels, a heating fluid inlet at one end of the heat exchange channels, and a heating fluid outlet at the opposite end of the heat exchange channels;
• a plurality of secondary plates subdividing the heat exchange channels into preheat channels and combustion channels;
• means for retaining a solid catalyst in the reaction channels;
• means for retaining a solid catalyst in the combustion channels;
• a heating fluid conduit for communicating the reactant outlet;
• a combustor defined by the heating fluid conduit or the heat exchange channel;
• and,
• an oxygen conduit for supplying an oxygen containing fluid to the combustor.

An apparatus for contacting reactants in a reaction stream with a catalyst in a reaction zone while directly heating reactants by combusting a portion of the reaction stream or components produced in the reaction zone in a heating zone while indirectly heating the reactants by contact with combustion gases formed in the heating zone, the apparatus comprising:

• a reactor body;
• a primary plate in the reactor body defining a first reactor volume with a first plurality of pockets on a first side of the plate and defining a second reactor volume with a second plurality of pockets on a second side of the plate;
• one or more first divider plates located in the reactor body and extending into at least two pockets in the first plurality of pockets to define at least two pairs of interconnected channels along a first flow path;
• one or more second divider plates located in the reactor body and extending into at least two pockets in the second plurality of pockets to define at least two pairs of interconnected channels along a second flow path;
• an inlet and an outlet for the first flow path defined by the reactor body;
• an inlet and an outlet for the second flow path defined by the reactor body;
• and a heat exchange surface provided by at least the primary plate or the first or second divider plates.