Compactgtl Limited

Gtl Microsystems Ag

Ian Frederick Zimmerman

Clive Derek Lee-tuffnell

David Leslie Segal

John William Stairmand

Michael Joseph Bowe

Jason Andrew Maude

David Charles William Blaikley

Clive Derek Lee-Tuffnell

Methane reacts with steam generating carbon monoxide and hydrogen in a first catalytic reactor; the resulting gas mixture undergoes Fischer-Tropsch synthesis in a second catalytic reactor. In the steam/methane reforming, the gas mixture passes through a narrow channel having mean and exit temperatures both in the range of 750&#xb0; C. to 900&#xb0; C., residence time less than 0.5 second, and the channel containing a catalyst, so that only reactions having comparatively rapid kinetics will occur. Heat is provided by combustion of methane in adjacent channels. The ratio of steam to methane may be about 1.5. Almost all methane will undergo the reforming reaction, almost entirely forming carbon monoxide. After Fischer-Tropsch synthesis, the remaining hydrogen may be fed back to the combustion channels. The steam for the reforming step may be generated from water generated by the chemical reactions, by condensing products from Fischer-Tropsch synthesis and by condensing water vapor generated in combustion.

Apparatus for steam-methane reforming

A catalytic reactor () comprises a plurality of sheets () defining flow channels () between them. Within each flow channel () is a foil () of corrugated material whose surfaces are coated with catalytic material apart from where they contact the sheets (). At each end of the reactor () are headers to supply gas mixtures to the flow channels (), the headers communicating with adjacent channels being separate. The reactor () enables different gas mixtures to be supplied to adjacent channels (), which may be at different pressures, and the corresponding chemical reactions are also different. Where one of the reactions is endothermic while the other reaction is exothermic, heat is transferred through the sheets () separating the adjacent channels (), from the exothermic reaction to the endothermic reaction. The reactor () may be used in a compact plant to perform steam/methane reforming, obtaining the necessary heat by catalytic methane combustion, and also for Fischer-Tropsch synthesis, so that the overall process involves conversion of methane to long-chain hydrocarbons.

Catalytic reactor

Methane is reacted with steam, to generate carbon monoxide and hydrogen in a first catalytic reactor (); the resulting gas mixture can then be used to perform Fisher-Tropsch synthesis in a second catalytic reactor (). In performing the steam/methane reforming, the gas mixture is passed through a narrow channel in which the mean temperature and exit temperature are both in the range 750&#xb0; C. to 900&#xb0; C. the residence time being less than 0.5 second, and the channel containing a catalyst, so that only those reactions that have comparatively rapid kinetics will occur. The heat is provided by combustion of methane in adjacent channels (). The ratio of steam to methane should preferably be 1.4 to 1.6, for example about 1.5. Almost all the methane will undergo the reforming reaction, almost entirely forming carbon monoxide. After performing Fischer-Tropsch synthesis, the remaining hydrogen is preferably fed back () to the combustion channels (). The steam for the reforming step is preferably generated from water generated by the chemical reactions, by condensing () the products from the Fischer-Tropsch synthesis and by condensing () water vapour generated in the combustion.

Process an apparatus for steam-methane reforming

A catalytic reactor comprises a plurality of fluid-impermeable plates defining side-by-side flow channels between them. Tight fitting within each flow channel is a sheet of corrugated material whose surfaces are coated with catalytic material. At each end of the flow channels there may be headers for supply gas mixtures to the flow channels, the headers communicating with adjacent channels being separate. The reactor enables different gas mixtures to be supplied to adjacent channels, which may be at different pressures, and the corresponding chemical reactions are also different. Where one of the reactions is endothermic while the other reaction is exothermic, heat is transferred through the wall of the tube separating the adjacent channels, from the exothermic reaction to the endothermic reaction. The provision of side=by-side flow channels provides for structural strength and for enhanced heat transfer.

A method for causing chemical reactions between fluids, comprising the steps of arranging a plurality of metal sheets for providing first fluid flow channels adjacent to and in heat transfer contact with second fluid flow channels between adjacent ones of the metal sheets, placing catalyst material within at least some of the flow channels, passing a first fluid mixture through the first fluid flow channels and a second fluid mixture through the second fluid flow channels, wherein the first fluid mixture is different from the second fluid mixture, each fluid mixture undergoing separate reactions, one of the reactions being endothermic while the other reaction is exothermic, and causing heat to transfer between the adjacent fluid flow channels.

A catalytic reactor comprises a plurality of fluid-impermeable plates defining flow channels between them. Tight fitting within each flow channel is a sheet of corrugated material whose surfaces are coated with catalytic material. At each end of the flow channels are headers to supply gas mixtures to the flow channels, the headers communicating with adjacent channels being separate. The reactor enables different gas mixtures to be supplied to adjacent channels, which may be at different pressures, and the corresponding chemical reactions are also different. Where one of the reactions is endothermic while the other reaction is exothermic, heat is transferred through the wall of the tube separating the adjacent channels, from the exothermic reaction to the endothermic reaction.

Methane is reacted with steam, to generate carbon monoxide and hydrogen in a first catalytic reactor; the resulting gas mixture can then be used to perform Fischer-Tropsch synthesis in a second catalytic reactor. In performing the steam/methane reforming, the gas mixture is passed through a narrow flow channel containing a catalyst structure on a metal substrate, and adjacent to a source of heat, in a time less than 0.5 s, so that only those reactions that have comparatively rapid kinetics will occur. Both the average temperature and the exit temperature of the channel are in the range 750&#xb0; to 900&#xb0; C. The ratio of steam to methane should preferably be 1.4 to 1.6, for example about 1.5. Almost all the methane will undergo the reforming reaction, almost entirely forming carbon monoxide. After performing Fischer-Tropsch synthesis, the remaining hydrogen is preferably used to provide heat for the reforming reaction.

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Wimborne, United Kingdom

Ian Frederick Zimmerman