Abstract: A reactor module for Fischer-Tropsch synthesis having a generally rectangular reactor block with a stack of plates defining flow channels for coolant and flow channels for the synthesis reaction arranged alternately in the block. The synthesis flow channels extend in a generally vertical direction between upper and lower faces of the reactor block and are defined by plates in combination with either bars or sheets such that each channel is of width no more than 200 mm. The coolant flow channels are oriented in the same direction, and communicate through distributor chambers with inlet and outlet ports at side faces of the reactor block. A plant may contain a multiplicity of such reactor modules operating in parallel, the modules being interchangeable and replaceable. The temperature control is enhanced by allowing the coolant flow to be parallel to the synthesis gas flow.

Abstract: A compact catalytic reactor defines a multiplicity of first and second flow channels arranged alternately, for an endothermic reaction and for an exothermic reaction respectively, and each containing a removable fluid-permeable catalytic insert to catalyze the reaction. The flow channels have a straight portion extending from one end face of the reactor and a linking portion that communicates between the end of the straight portion and at least one side face of the reactor, wherein the straight portion and the linking portion are defined at least in part by fin structures. The fm structures of the linking portion may be perforated, so that there are perforations aligned with each straight portion, but at the end of the reactor each line of perforations is obstructed. Removal of the obstructions enables the catalytic inserts to be pushed out of the flow channels when they are spent.

Abstract: A gas-to-liquids process and plant for treating natural gas, in which the natural gas is subjected to expansion through a flow restrictor so as to undergo cooling through the Joule Thomson effect, enables liquids to be separated from the gas stream. The natural gas may be cooled before it reaches the flow restrictor by heat exchange with fluid that has passed through the flow restrictor. This decreases the proportion of longer-chain hydrocarbons in the natural gas, which may simplify subsequent processing, and may enable the size of the plant to be decreased.

Abstract: An activation process for a Fischer-Tropsch catalyst is described. The process comprises a first reduction step; an oxidation step; the introduction of the catalyst into a Fischer-Tropsch reactor; and a second reduction step.

Abstract: A compact catalytic reactor (20) comprises a channel for a rapid reaction having an inlet (26) for a gas mixture to undergo the reaction. The channel is provided with two different catalyst structures (32, 34), a first catalyst structure (32) in the vicinity of the inlet (26) and a second catalyst structure (34) further from the inlet, such that a gas mixture supplied to the inlet flows past them both. The first catalyst structure (32) has little catalytic activity for the rapid reaction, whereas the second catalyst structure (34) has catalytic activity for the rapid reaction. This is applicable to combustion of gas mixtures containing hydrogen, for which the first catalyst structure (32) may comprise uncoated oxidized aluminum-containing ferritic steel, while the second catalyst structure (34) may incorporate Pt and/or Pd in an alumina support. Exhaust gases may also be recycled to the inlet (26) to inhibit combustion.

Abstract: A reactor defining first and second flow channels within the reactor, wherein the first flow channels are for fluids that undergo an exothermic reaction and contain a catalyst for the exothermic reaction and wherein the second flow channels are for a heat-removing fluid. Further wherein the channels at each end of the reactor are such that no heat is generated within them, the channels in which no heat is generated being non-flow channels which are blocked off at one or both of their ends so no fluids flow through those channels.

Abstract: A compact catalytic reactor defining a multiplicity of alternately arranged first and second flow channels, for carrying first and second fluids, respectively. At least the first fluids undergo a chemical reaction. Each first flow channel contains a removable gas-permeable catalyst structure incorporating a metal foil substrate, said catalyst structure defining flow paths therethrough. The substrate comprises a stack of spaced-apart foils wherein the catalyst structure incorporates a multiplicity of resilient strips which are bent out from the foil substrate so as to project from the substrate and to support said catalyst structure resiliently spaced away from at least one adjacent wall of said channel. Each strip being connected to said catalyst structure only at an end or ends of said strip, and being integral with said foil.

Abstract: A compact catalytic reactor defines a multiplicity of first and second flow channels arranged alternately in the reactor, for carrying first and second fluids, respectively, wherein at least the first fluids undergo a chemical reaction. Each first flow channel containing a removable gas-permeable catalyst structure (20) incorporating a metal substrate, the catalyst structure defining flow paths therethrough, with catalytic material on at least some surfaces of each such path. The catalyst structure also incorporates a multiplicity of projecting resilient lugs (22) which support the catalyst structure (20) spaced away from at least one adjacent wall of the channel (17).

Abstract: A catalytic reactor (40) comprises a plurality of sheets (42) defining flow channels (44) between them. Within each flow channel (44) is a foil (46) of corrugated material whose surfaces are coated with catalytic material apart from where they contact the sheets (44). At each end of the reactor (40) are headers to supply gas mixtures to the flow channels (44), the headers communicating with adjacent channels being separate. The reactor (40) enables different gas mixtures to be supplied to adjacent channels (44), 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 (42) separating the adjacent channels (44), from the exothermic reaction to the endothermic reaction.

Abstract: A method of operation of one or more chemical reactors, wherein each reactor defines first flow channels for a chemical reaction process in proximity to second flow channels for heat transfer, and each reactor is provided with fluid connections for bringing about flows of respective fluids through the first and second flow channels, involves the steps of shutting down the flows of fluids through at least one of the first and second flow channels, and then changing the fluid connections, and then reopening the fluid connections. There is no change in the chemical reaction process performed by the reactors. The change to the fluid connections is preferably such as to achieve a flow reversal. This may involve turning the reactor itself around, or changing the arrangement of ducts connected to the reactor. This changes the thermal stress distribution within the reactor, and can consequently increase the reactor's operational lifetime.

Abstract: Methane is reacted with steam, to generate carbon monoxide and hydrogen in a first catalytic reactor (14); the resulting gas mixture can then be used to perform Fisher-Tropsch synthesis in a second catalytic reactor (26). 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° C. to 900° 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 (17). 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 (34) to the combustion channels (17).

Abstract: An insertion apparatus is provided for inserting at least one catalytic insert into each of a multiplicity of reactor channels. The apparatus includes a magazine configured to locate a multiplicity of catalytic inserts, a guide element for guiding the movement of a catalytic insert as it is inserted into the reaction channel, and a pushing member to push a catalytic insert out of the magazine, through the guide element, and into a reactor channel. An automated method for inserting catalytic inserts into reactor channels is also provided. The method includes the steps of: aligning the insert with a reaction channel, and pushing the insert through a guide element into the channel.

Abstract: A compact catalytic reactor defines a multiplicity of first and second flow channels arranged alternately, for an endothermic reaction and for an exothermic reaction respectively, and each containing a removable fluid-permeable catalytic insert to catalyze the reaction. The flow channels have a straight portion extending from one end face of the reactor and a linking portion that communicates between the end of the straight portion and at least one side face of the reactor, wherein the straight portion and the linking portion are defined at least in part by fin structures. The fm structures of the linking portion may be perforated, so that there are perforations aligned with each straight portion, but at the end of the reactor each line of perforations is obstructed. Removal of the obstructions enables the catalytic inserts to be pushed out of the flow channels when they are spent.

Abstract: A catalyst support is made by coating a metal substrate with a solution containing a precursor for a ceramic and an amphiphilic compound, and treating the coating such that it forms a micelle structure. The coating is then treated to form a mesoporous ceramic coating on the metal substrate. The micelle structure acts as a template, so that the pores are of regular size. The active catalytic material can then be deposited in the pores. The metal substrate may for example be a corrugated foil, which can enable reaction heat to be dissipated from hot spots.

Abstract: A catalytic reaction module (10) for performing an endothermic reaction such as steam methane reforming, includes separate reactor blocks (12), each reactor block defining a multiplicity of first and second flow channels (15, 16) arranged alternately within the block to ensure thermal contact between the first and second flow channels. The reactor blocks (12a, 12b) may be arranged and connected for series flow of a combustible gas mixture in the first flow channels (15) and also of a gas mixture to undergo the endothermic reaction in the second flow channels (16). This enables the combustion process to be carried out in stages, with the option of cooling the combustion gases between stages, and introducing additional fuel and additional air.

Abstract: A compact catalytic reactor for Fischer-Tropsch synthesis defines a multiplicity of first and second flow channels arranged alternately in the reactor, for carrying a gas mixture which undergoes Fischer-Tropsch synthesis, and a coolant fluid, respectively. Each first flow channel contains a removable gas-permeable catalyst structure incorporating a metal substrate. A multiplicity of flow paths are defined through the catalyst structure, and the voidage, that is to say the proportion of the cross-sectional area of the first flow channel constituted by the said multiplicity of flow paths, is between 25% and 70%. This provides an optimum balance between productivity and selectivity, so that operation of the reactor can be economic and controllable.

Abstract: A compact catalytic reactor for Fischer-Tropsch synthesis (50) comprises a reactor module (70) defining a multiplicity of first and second flow channels arranged alternately, for carrying a gas mixture, and a coolant respectively. A removable gas-permeable catalyst structure (82) with a substrate for example of metal foil is provided in each flow channel in which the synthesis reaction is to occur. The reactor module (70) is enclosed within a pressure vessel (90), the pressure within the pressure vessel being arranged to be at a pressure substantially that of the high pressure reacting gas mixture. Consequently all the flow channels within the module are either at the pressure of their surroundings, or are under compression; no parts are under tension. This simplifies the design of the module, and increases the proportion of reactor volume which can be occupied by the catalyst.

Abstract: 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.

Abstract: 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.

Abstract: A catalyst structure comprises a foil strip (10) acting as the substrate, and which has been cut and shaped so as to define a multiplicity of peaks (15) and troughs (16) each with its axis extending across the foil, such that peaks and troughs alternate across the foil strip (10). Such a corrugated substrate may be provided with a ceramic coating incorporating a catalytic material. The corrugations enhance turbulence within a flow channel of a compact catalytic reactor.