Process and apparatus for conducting simultaneous endothermic and exothermic reactions
AssigneeVelocys, Inc.
InventorsSteven T. Perry, Ravi Arora, Martyn Twigg, Bin Yang, Thomas Yuschak, Kai Tod Paul Jarosch, Eric Hans Drescher, Franck Letellier, Anders Gabrielsson
Life of this patent
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Abstract
This invention relates to a process and an apparatus for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor. A start-up procedure for the microchannel reactor is disclosed.
Claims50
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer comprising a plurality of process microchannels and a heat exchange layer, the process microchannels containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) starting the flow of a first process reactant in the process microchannels, the first process reactant comprising steam;
- (C) flowing a second process reactant in the process microchannels, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- and
- (E) increasing the temperature in the process layer to a desired operating temperature;
- wherein steps (A), (B), (C), (D) and (E) are conducted sequentially with the exception that step (B) is conducted prior to or concurrently with step (C);
- and
- wherein the catalyst is not activated prior to step (A).
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein a mixture of the first reactant and the second reactant is formed during step (C), and during step (B) the process comprises flowing nitrogen in the process layer and heating the process layer until the temperature in the process layer exceeds the dew point of the mixture of the first reactant and the second reactant in step (C) at the pressure within the process layer, then replacing the nitrogen in the process layer with steam.
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein steps (A), (B), (C), (D) and (E) are conducted sequentially.
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein step (C) is conducted prior to step (B), and the intermediate temperature is below about 300° C.
A process for conducting simultaneous steam reforming and oxidation reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process being conducted in a facility where a hydrogen enriched stream comprising hydrogen and one or more hydrocarbons is produced downstream of the microchannel reactor, the process including a start-up procedure comprising:
- (A) transferring heat from the heat exchange layer to the process layer to increase the temperature in the process layer;
- (B) flowing one or more process reactants in the process layer and conducting a steam reforming reaction to provide a synthesis gas product comprising hydrogen;
- (C) using at least a portion of the synthesis gas product and/or separating part of the hydrogen from the synthesis gas product downstream of the reactor to provide the hydrogen enriched stream;
- (D) conducting an oxidation reaction in the heat exchange layer to produce heat using a heat exchange reactant mixture comprising an oxygen source and part or all of the hydrogen enriched stream;
- (E) wherein the flow of hydrogen in the hydrogen enriched stream used in the oxidation reaction increases during the start-up procedure.
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein subsequent to the start-up procedure, an endothermic reaction process is conducted in the process layer, and an exothermic reaction process is conducted in the heat exchange layer;
- and
- wherein a product is formed in the process layer, and part of the product formed in the process layer is used as an exothermic reactant in the heat exchange layer.
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein subsequent to the start-up procedure, an endothermic reaction process is conducted in the process layer, and an exothermic reaction process is conducted in the heat exchange layer;
- and
- wherein synthesis gas is formed in the process layer, the synthesis gas comprising CO and H2, part of the H2 being separated from the synthesis gas, the separated H2 flowing into the heat exchange layer as an exothermic reactant.
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein the process layer comprises a process heat exchange section and a process reaction section, the process reaction section being downstream of the process heat exchange section;
- and
- wherein a pre-reforming catalyst is positioned in the process heat exchange section.
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein the heat exchange layer comprises a heat exchange layer heat exchange section and a heat exchange layer reaction section, the heat exchange layer reaction section being downstream of the heat exchange layer heat exchange section;
- and
- wherein a hydrogenolysis catalyst is positioned in the heat exchange layer heat exchange section.
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein an ignition catalyst and a clean-up catalyst are positioned in the heat exchange layer.
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein the process layer comprises a process reactant layer, a process product layer positioned adjacent to the process reactant layer, and a process u-turn positioned at an end of the process reactant layer and at an end of the process product layer to allow for the flow of fluid from the process reactant layer to the process product layer, the process heat exchange section and the process reaction section being positioned in the process reactant layer.
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein the heat exchange layer comprises an exothermic reactant layer, oxygen source layer, exhaust layer, and a heat exchange u-turn positioned at an end of the exothermic reactant layer and at an end of the exhaust layer to allow for the flow of fluid from the exothermic reactant layer to the exhaust layer, the exothermic reactant layer having a heat exchange section and a reaction section.
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein the heat exchange layer comprises a exothermic reactant layer, the exothermic reactant layer including an exothermic reactant rich section and an exothermic reactant lean section, the exothermic reactant rich section being upstream from the exothermic reactant lean section, and an ignition catalyst positioned in the exothermic reactant rich section.
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein an exothermic reaction is conducted in the heat exchange layer to produce heat and a dry exhaust gas, the dry exhaust gas containing no more than about 5% by volume of methane or hydrogen.
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein an exothermic reaction is conducted in the heat exchange layer, the exothermic reaction comprising the reaction of a fuel with an oxygen source, an exhaust gas being produced, the amount of oxygen in the exhaust gas while operating at the intermediate temperature being in the range from about 10% to about 21% by volume.
A process for conducting simultaneous endothermic and exothermic reactions in a microchannel reactor, the microchannel reactor comprising a process layer and a heat exchange layer, the process layer containing a catalyst, the process including a start-up procedure comprising:
- (A) increasing the temperature in the process layer from ambient temperature to an intermediate temperature;
- (B) flowing a first process reactant in the process layer;
- (C) flowing a second process reactant in the process layer, the second process reactant comprising a hydrocarbon;
- (D) activating the catalyst by contacting the catalyst with the second process reactant;
- (E) increasing the temperature in the process layer to a desired operating temperature;
- and
- wherein an exothermic reaction is conducted in the heat exchange layer, the exothermic reaction comprising the reaction of a fuel with an oxygen source, an exhaust gas being produced, the amount of oxygen in the exhaust gas while operating at the desired operating temperature is in the range from about 2% to about 10% by volume.
Dependencies are inferred from the claim text.