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 valve assembly (10) comprises a vortex chamber (14) with an axial outlet port (20), a main inlet port (16) for a fluid to be controlled, and a substantially tangential inlet port (25); the fluid enters through an inlet chamber (13) in which is a mechanical valve (26) movable so as to obstruct fluid flow into the vortex chamber (14). A duct (24) links the inlet chamber (13) to the tangential inlet port (25) of the vortex chamber. The position of the mechanical valve (26) affects the flow of fluid through the duct (24), so the vortex chamber (14) amplifies the effect of the mechanical valve. Further movement of the valve (26) closes off flow altogether (40). The assembly may include a weir (36) in the outlet, to separate gas and liquid phases.

Abstract: A valve system (10) controls the fluid flow between an inlet (12) and an outlet (14). The system (10) splits the flow into two parallel flow ducts (15, 16) and recombines the flows through opposed tangential inlets (18) and (19) of a fluidic vortex valve (20) which has an axial outlet (22). An adjustable valve (24) controls the flow through one of the parallel flow ducts (15), controlling the strength of the vortex generated within the vortex valve (20). Hence a small valve (24) can control and adjust the flows in both ducts (15 and 16).

Abstract: Small crystals are made by mixing a solution of a desired substance with an anti-solvent in a fluidic vortex mixer in which the residence time is less than 1 s, for example 10 ms. The liquid within the fluidic vortex mixer (12) is subjected to high intensity ultrasound from a transducer (20, 22) in or on the wall of the mixer, or coupled to a pipe supplying liquid to the mixer. The solution very rapidly becomes supersaturated, and the ultrasound can induce a very large number of nuclei for crystal growth. Small crystals, for example less than 5 ?m, are formed that may be of a suitable size for use in inhalers.

Abstract: A chemical plant for performing a chemical reaction between particles of a material such as lithium metal, and a reagent such as butyl chloride in solution in hexane, in which one reaction product is a solid material, includes a reaction vessel (12). Several ultrasonic transducers (16) are attached to a wall of the vessel (12) so as to irradiate ultrasonic waves into the vessel, the vessel being large enough that each transducer irradiates into fluid at least 0.1 m thick, each transducer irradiating no more than 3 W/cm2, and the transducers being sufficiently close to each other and the number of transducers being sufficiently high that the power dissipation within the vessel is at least 10 W/liter but no more than 200 W/liter. The high intensity of ultrasound ensures that lithium chloride is cleaned off the surface of lithium metal particles throughout the vessel (12).

Abstract: A valve assembly (10) comprises a vortex chamber (14) with an axial outlet port (20), a main inlet port (16) for a fluid to be controlled, and a substantially tangential inlet port (25); the fluid enters through an inlet chamber (13) in which is a mechanical valve (26) movable so as to obstruct fluid flow into the vortex chamber (14). A duct (24) links the inlet chamber (13) to the tangential inlet port (25) of the vortex chamber. The position of the mechanical valve (26) affects the flow of fluid through the duct (24), so the vortex chamber (14) amplifies the effect of the mechanical valve. Further movement of the valve (26) closes off flow altogether (40). The assembly may include a weir (36) in the outlet, to separate gas and liquid phases.

Abstract: Small crystals are made by mixing a solution of a desired substance with an anti-solvent in a fluidic vortex mixer in which the residence time is less than 1 s, for example 10 ms. The liquid within the fluidic vortex mixer (12) is subjected to high intensity ultrasound from a transducer (20, 22) in or on the wall of the mixer, or coupled to a pipe supplying liquid to the mixer. The solution very rapidly becomes supersaturated, and the ultrasound can induce a very large number of nuclei for crystal growth. Small crystals, for example less than 5 &mgr;m, are formed that may be of a suitable sise for use in inhalers.

Abstract: A chemical plant for performing a chemical reaction between particles of a material such as lithium metal, and a reagent such as butyl chloride in solution in hexane, in which one reaction product is a solid material, includes a reaction vessel (12). Several ultrasonic transducers (16) are attached to a wall of the vessel (12) so as to irradiate ultrasonic waves into the vessel, the vessel being large enough that each transducer irradiates into fluid at least 0.1 m thick, each transducer irradiating no more than 3 W/cm2, and the transducers being sufficiently close to each other and the number of transducers being sufficiently high that the poser dissipation within the vessel is at least 10 W/litre but no more than 200 W/litre. The high intensity of ultrasound ensures tat lithium chloride is cleaned off the surface of the lithium metal particles throughout the vessel (12).

Abstract: Solvent containing a product (or precursor for the product) and anti-solvent are introduced via tangential inputs respectively 17,18 of a fluidic vortex mixer 11. The emerging mix from axial outlet 20 is supplied directly to a precipitate entrapment device such as filter bed 12 so that precipitate is removed from the solution before the precipitated particles have time to grow. Filtrate is treated in a reduced pressure evaporator 13 to recover anti-solvent and return concentrated solution for combining with a product make up stream at 19 and return to tangential input 17 of the fluidic vortex mixer.

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.