Abstract: Apparatuses for use in plants for processing methane, the apparatuses comprising a plurality of reaction modules each including a plurality of Fischer-Tropsch reactors operable to convert a gaseous mixture including carbon monoxide and hydrogen to a liquid hydrocarbon. Each module may be disconnected and taken away for servicing while allowing the plant to continue to operate. In some of the apparatuses, each Fischer-Tropsch reactor comprises a plurality of metal sheets arranged as a stack to define first and second flow channels for flow of respective fluids, the channels being arranged alternately to ensure good thermal contact between the fluids in the channels.

Abstract: 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° C. to 900° 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.

Abstract: 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° C. to 900° 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.

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: 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: 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 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: 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 ranges 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: 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 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.

Abstract: A catalytic reactor comprises a plurality of sheets defining flow channels between then. Within each flow channel is a foil of corrugated material whose surfaces are coated with catalytic material. The flow channels extend in transverse dire options, but the foils are shaped to cause the gas in those channels to flow at least partly in counter current to the gas flowing in the other channels. The reactor incorporates header chambers to supply gas mixtures to the flow channels, each header being in the form of a cap attached to the outside of the back and covering a face of the stack. Hence different gas mixtures are supplied to the different channels which may be at different pressures, and the corresponding chemical reactions are also different, and heat is transferred through the sheets separating the adjacent channels. When the catalyst in one set of flow channels becomes spent, it can be replaced by removing a header.

Abstract: A catalytic reactor comprises a plurality of thin tray-like metal sheets each with a peripheral rim and arranged as a stack to define first gas flow channels between adjacent sheets, alternating with second gas flow channels between adjacent sheets, so as to ensure good thermal contact between gases in the first and the second gas flow channels. Each sheet also defines at least four apertures for flow of gases, and tubes and seal apertures in one sheet to corresponding apertures in the adjacent sheet. The gas flows through the channels may be guided by corrugations, and are preferably in countercurrent in adjacent channels. Appropriate catalysts are coated onto the sheets and in the two gas flow channels.

Abstract: A catalytic reactor comprises a stack of sheets defining flow channels between them. Within each flow channel is a flexible wire structure whose surfaces are coated with catalytic material. Flow channels for a first gas extend along S-shaped curved paths whereas the flow channels for a second gas are straight. The reactor incorporates header chambers to supply gas mixtures to the flow channels, each header chamber being a rectangular cap attached to a face of the stack. The reactor enables different gas mixtures to be supplied to adjacent channels, which nay 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. When the catalyst in one set of flow channels becomes spent, it can be replaced by removing a header.

Abstract: 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° to 900° 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.

Abstract: A catalytic reactor (10) comprises a stack of sheets (12) defining flow channels (14) between them. Within each flow channel (14) is a flexible wire structure (16) whose surfaces are coated with catalytic material. Flow channels (14, 14a) for a first gas extend along S-shaped curved paths whereas the flow channels (14b) for a second gas are straight. The reactor (10) incorporates header chambers (18) to supply gas mixtures to the flow channels (14), each header chamber being a square cap attached to a face of the stack. The reactor (10) enables different gas mixtures to be supplied to adjacent channels (14), 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 (12) separating the adjacent channels (14), from the exothermic reaction to the endothermic reaction.

Abstract: A catalytic reactor (10) comprises a plurality of sheets (12, 13) defining flow channels (14, 18) between them. Within each flow channel (14, 18) is a foil (16, 20) of corrugated material whose surfaces are coated with catalytic material. The flow channels (14, 18) extend in transverse directions, but the foils (20) are shaped to cause the gas in those channels (18) to flow at least partly in countercurrent to the gas flowing in the other channels (14). The reactor (20) incorporates header chambers (22, 24) to supply gas mixtures to the flow channels (14, 18), each header being in the form of a cap attached to the outside of the back and covering a face of the stack. Hence different gas mixtures are supplied to the different channels (14, 18) which may be at different pressures, and the corresponding chemical reactions are also different, and heat is transferred through the sheets (12, 13) separating the adjacent channels.

Abstract: A catalytic reactor consists of a plurality of thin tray-like metal sheets (12, 13) each with a peripheral rim (14) and arranged as a stack to define first gas flow channels between adjacent sheets, alternating with second gas flow channels between adjacent sheets, so as to ensure good thermal contact between gases in the first and the second gas flow channels. Each sheet (12) and (13) also defines at least four apertures (16, 17, 18, 19) for flow of gases, and tubes (20) and (21) seal apertures in one sheet to corresponding apertures in the adjacent sheet. The gas flows through the channels may be guided by corrugations (15), and are preferably in countercurrent in adjacent channels. Appropriate catalysts are coated onto the sheets (12) and (13) in the two gas flow channels.

Abstract: A catalytic reactor (10) comprises a plurality of fluid-impermeable elements (tubes or plates) (12) defining flow channels (15) between them. Tight fitting within each flow channel (15) is a sheet (16) of corrugated material whose surfaces are coated with catalytic material. At each end of the reactor (10) are headers (18) to supply gas mixtures to the flow channels (15), the headers communicating with adjacent channels being separate. The reactor (10) enables different gas mixtures to be supplied to adjacent channels (15), 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 (12) separating the adjacent channels (15), from the exothermic reaction to the endothermic reaction.