Support structures for a catalyst

In a catalytic reactor for use in continuous high temperature reactions comprising a monolithic catalyst structure made up of a multiplicity of longitudinally disposed channels with inlet and outlet ends for passage of a flowing reaction gas mixture secured within a reaction chamber by means of a support structure comprising a monolithic open cellular structure wherein the walls of the cells are formed by strips of high temperature resistant metal or ceramic material having cellular openings in fluid communication with the inlet and outlet ends of the channels in the catalyst structure, said open cellular support structure being positioned at the inlet and outlet ends of the catalyst structure to abut against the ends of the catalyst structure and having a cross-section which essentially covers the end faces of the catalyst structure, the improvement which comprises:

• a) sizing the catalyst structure such that it has a reduced cross-sectional area, taken in a direction perpendicular to its longitudinal axis, relative to the cross-sectional area of the reaction chamber such that an annular space is formed between the outer periphery of the catalyst structure and the inner surface of the reaction chamber as defined by the reaction chamber wall, said annular space being sized to allow for thermal expansion of the catalyst structure which occurs during the high temperature reaction without causing the catalyst structure to be compressed and deformed by pressing against the reaction chamber wall;
• b) obstructing the flow of reaction gas mixture through the annular space which is formed between the outer periphery of the catalyst structure and the inner surface of the reaction chamber wall by inserting one or more flexible metal flanges which extend from the outer peripheral surface of the catalyst structure to the inner surface of the reaction chamber wall to substantially block the flow of reaction gas mixture which would otherwise by-pass the catalyst structure, said metal flanges being sufficiently flexible that the metal flanges will bend as the catalyst structure undergoes thermal expansion without placing sufficient stress on the catalyst structure to cause localized deformation of the catalyst structure at the points of contact with the catalyst structural wall;
• c) centering the catalyst structure and the open cellular support structure abutting against the catalyst structure in a stable position within the reaction chamber such that the annular space between the outer periphery of the catalyst structure and the inner surface of the reaction chamber is substantially the same around the entire periphery of the catalyst structure by means of three or more mated radial splines and struts mounted on the peripheral surface of the open cellular support structure adjacent to the inner wall surface of the reaction chamber and/or on the peripheral surface of the catalyst structure with the corresponding mating spline or strut being mounted on the inner surface of the reaction chamber wall opposite from the spline or strut on the support structure and/or catalyst structure, said strut being meshed into the groove formed by said spline to hold the catalyst structure in place, with the depth of the groove in the spline and/or height of the strut being sized to allow for thermal expansion of the open cellular support structure and/or the catalyst structure which occurs during the high temperature reaction, while maintaining the centered position of the catalyst structure within the reaction chamber;
• d) stabilizing the open cellular support structure against deformation caused by the axial load exerted on the face of the support structure in a direction parallel to the longitudinal axis of the catalyst structure during passage of the flowing reaction gas mixture by means of a center support member disposed in an axial bore through the catalyst structure which is secured to the inlet support structure and the outlet support structure and extends through the center of the catalyst structure in a longitudinal direction, whereby a force exerted on the outlet side support structure by the flowing gas reaction gas mixture is transferred via the center support member to the inlet side support structure;
• and
• e) providing additional structural integrity to the open cellular support structure located at the inlet and the outlet ends of the catalyst structure by means of a solid, high temperature resistant metal band bonded to the peripheral surface of the open cellular support structure, said metal band being thicker in width than the strips of high temperature resistant metal or ceramic material making up the cell walls of the open cellular support structure and having slots cut in its outer peripheral portion to provide sufficient flexibility in the metal band to absorb the thermal expansion of the thinner open cellular structure which occurs during the high temperature reaction without causing the open cellular support structure to deform due to the difference in thermal expansion between the open cellular structure and the metal band bonded thereto.