Integrated boiler, superheater, and decomposer for sulfuric acid decomposition

A chemical reactor for processing a process fluid, comprising a bayonet-type, dual-tube counter-flow heat exchanger, comprising:

• an outer bayonet tube closed at the top and open at the bottom;
• an inner tube open at the top and bottom ends, and centered inside of the outer tube;
• for providing a return flow path from the closed end of the outer bayonet tube;
• an outer annular flow space formed between the inner surface of the outer bayonet tube and the outer surface of the inner tube;
• catalyst media disposed in the outer annular flow space near the closed end of the outer bayonet tube;
• a central baffle centered inside of the inner tube;
• and
• an inner annular flow space formed between the inner surface of the inner tube and the outer surface of the central baffle;
• wherein process fluid enters the reactor at the bottom of the outer bayonet tube, flows through the outer annular flow space towards the top of the outer bayonet tube, turns around at the top, returns back through the inner tube, flowing inside of the inner annular flow space, and exits at the bottom of the inner tube;
• wherein the outer bayonet tube, inner tube, and central baffle are made of a ceramic material selected from the group consisting of silicon carbide, silicon carbide alloy, glass, quartz, and alumina;
• wherein the catalyst media comprises a catalytic material selected from the group consisting of platinum, iron oxide, rhodium, and metal oxides;
• wherein the radial thickness of both the outer annular flow space and the inner annular flow space are less than about 1 mm;
• wherein the axial length of the catalytic media is less than or equal to ⅓ of the length of the outer bayonet tube;
• wherein the inner tube has a variable diameter;
• and wherein the diameter of that portion of the inner tube that contacts the catalyst media is smaller than the diameter of that portion of the inner tube which does not contact the catalyst media;
• wherein the reactor does not have any gaskets or seals for making fluidic connections that operate at temperatures greater than 260 C;
• and
• wherein the central baffle comprises a hollow central baffle tube with a closed upper end, and an interior volume.

A process for decomposing sulfuric acid into SO2, O2, and H2O;

• comprising:
• a) providing a chemical reactor comprising a bayonet-type, dual-tube counter-flow heat exchanger;
• the heat exchanger comprising:
• an outer bayonet tube closed at the top and open at the bottom;
• an inner tube open at the top and bottom ends, and centered inside of the outer tube;
• for providing a return flow path from the closed end of the outer bayonet tube;
• an outer annular flow space formed between the inner surface of the outer bayonet tube and the outer surface of the inner tube;
• catalyst media disposed in the outer annular flow space near the closed end of the outer bayonet tube;
• a central baffle centered inside of the inner tube;
• and
• an inner annular flow space formed between the inner surface of the inner tube and the outer surface of the central baffle;
• b) supplying heat from an outside source to the exterior surface of the outer bayonet tube;
• c) supplying an inlet stream of concentrated liquid sulfuric acid (H2SO4), to the outer annular flow space at the bottom of the outer bayonet tube;
• d) flowing the sulfuric acid in the outer annular flow space, and heating the acid beyond the boiling point to form vapors of sulfuric acid;
• e) superheating the vapors to at least 700 C, thereby decomposing the acid vapors into SO3 and H2O;
• f) passing the superheated vapors of sulfuric acid through the catalytic media, thereby forming additional decomposition products comprising SO2, O2, and H2O;
• g) flowing the decomposition products, including any un-reacted sulfuric acid, back down through the inner tube, through the inner annular flow space, towards the bottom of the heat exchanger;
• h) recuperating sensible heat from the decomposition products by transferring sensible heat from the decomposition products flowing in the inner annular flow space through the inner tube into the acid flowing in the outer annular flow space;
• and
• i) discharging the decomposition products, and any unreacted sulfuric acid, from the bottom of the heat exchanger.

A process for decomposing sulfuric acid into SO2, O2, and H2O;

• comprising:
• a) providing a chemical reactor comprising a bayonet-type, dual-tube counter-flow heat exchanger;
• the heat exchanger comprising:
• an outer bayonet tube closed at the top and open at the bottom;
• an inner tube open at the top and bottom ends, and centered inside of the outer tube;
• for providing a return flow path from the closed end of the outer bayonet tube;
• an outer annular flow space formed between the inner surface of the outer bayonet tube and the outer surface of the inner tube;
• catalyst media disposed in the outer annular flow space near the closed end of the outer bayonet tube;
• a central baffle centered inside of the inner tube;
• and
• an inner annular flow space formed between the inner surface of the inner tube and the outer surface of the central baffle;
• b) supplying heat from an outside source to the exterior surface of the outer bayonet tube;
• c) supplying an inlet stream of concentrated liquid sulfuric acid (H2SO4), to the outer annular flow space at the bottom of the outer bayonet tube;
• d) flowing the sulfuric acid in the outer annular flow space, and heating the acid beyond the boiling point to form vapors of sulfuric acid;
• e) superheating the vapors to at least 700 C, thereby decomposing the acid vapors into SO3 and H2O;
• f) passing the superheated vapors of sulfuric acid through the catalytic media, thereby forming additional decomposition products comprising SO2, O2, and H2O;
• g) flowing the decomposition products, including any un-reacted sulfuric acid, back down through the inner tube, through the inner annular flow space, towards the bottom of the heat exchanger;
• h) recuperating sensible heat from the decomposition products by transferring sensible heat from the decomposition products flowing in the inner annular flow space through the inner tube into the acid flowing in the outer annular flow space;
• and
• i) discharging the decomposition products, and any unreacted sulfuric acid, from the bottom of the heat exchanger;
• wherein the inlet fluid temperature is less than or equal to 100 C;
• and the exit temperature of the decomposition products is less than or equal to 260 C;
• wherein the temperature of the catalytic media is 700 to 900 C;
• wherein more than 35% of the incoming sulfuric acid is decomposed into SO2, O2, and H2O decomposition products;
• and
• wherein 40%, or less, of the lower end of the outer bayonet tube is not externally heated.

A process for decomposing sulfuric acid into SO2, O2, and H2O;

• comprising:
• a) providing a chemical reactor comprising a bayonet-type, dual-tube counter-flow heat exchanger;
• the heat exchanger comprising:
• an outer bayonet tube closed at the top and open at the bottom;
• an inner tube open at the top and bottom ends, and centered inside of the outer tube;
• for providing a return flow path from the closed end of the outer bayonet tube;
• an outer annular flow space formed between the inner surface of the outer bayonet tube and the outer surface of the inner tube;
• catalyst media disposed in the outer annular flow space near the closed end of the outer bayonet tube;
• a central baffle, centered inside of the inner tube;
• and
• an inner annular flow space formed between the inner surface of the inner tube and the outer surface of the central baffle;
• wherein the central baffle comprises a hollow central baffle tube with a closed upper end, and an interior volume;
• and
• wherein the hollow central baffle tube further comprises gas-selective permeable means for selectively passing one or more gaseous species from the inner annular flow space into the interior volume of the central tube;
• b) supplying heat from an outside source to the exterior surface of the outer bayonet tube;
• c) supplying an inlet stream of concentrated liquid sulfuric acid (H2SO4), to the outer annular flow space at the bottom of the outer bayonet tube;
• d) flowing the sulfuric acid in the outer annular flow space, and heating the acid beyond the boiling point to form vapors of sulfuric acid;
• e) superheating the vapors to at least 700 C, thereby decomposing the acid vapors into SO3 and H2O;
• f) passing the superheated vapors of sulfuric acid through the catalytic media, thereby forming additional decomposition products comprising SO2, O2, and H2O;
• g) flowing the decomposition products, including any un-reacted sulfuric acid, back down through the inner tube, through the inner annular flow space, towards the bottom of the heat exchanger;
• h) recuperating sensible heat from the decomposition products by transferring sensible heat from the decomposition products flowing in the inner annular flow space through the inner tube into the acid flowing in the outer annular flow space;
• i) selectively separating, using the gas-selective permeable means, at least one gaseous species of decomposition product from the inner annular flow space into the interior volume of the hollow central baffle tube;
• j) discharging the separated-out at least one gaseous species of decomposition product from the interior volume of the hollow central baffle tube at the bottom of the heat exchanger;
• and
• k) discharging, as a separate stream from the stream in step j), the remaining un-separated decomposition products, plus any unreacted sulfuric acid, from the inner annular flow space, at the bottom of the heat exchanger.